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"One Off" 409 Chevy Induction

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  • "One Off" 409 Chevy Induction

    Been pretty busy in the shop lately so I'm sorry that I have neglected you Bang Shift members. I want to share a project with you guys, get you up to speed, and let you follow the remaining progress.

    I've been asked to build a "one off" induction for Andy Leach of CAL Automotive Creations (guys who built the 40 Ford Ridler Award Winner recently that Scott aka Dieselgeek tuned). These guys build some of the most beautiful cars I have ever laid eyes on! You can check out some of their projects here. http://www.calautocreations.com/

    Luckily I was able to get a good friend to get me some raw castings from Hilborn to be able to take this project on. Normally they will not sell them this way but when your friends with Gene Adams who worked there for years you can get a little extra pull! I plan to use the majority of the castings but in the end it will not look like a typical Hilborn. Lots of machining to be done to get them to fit (396 castings if I recall) but here is what things look like as raw unmachined castings.

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    Serial #000 this doesn't exist! Truly one off!
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    Nick Smithberg
    www.smithbergracing.com

  • #2

    Re: "One Off" 409 Chevy Induction

    Here is the start of the fun part, various machining operations.

    Here I'm establishing a few flat areas on the casting after I leveled it.
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    Drilled and tapped these bosses which are typically used for EFI Injector Bungs from Hilborn. These holes I will be using to mount onto my fixture and will be removing them down the road.
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    Truing up the intake flange.
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    Nick Smithberg
    www.smithbergracing.com

    Comment


    • #3

      Re: "One Off" 409 Chevy Induction

      More fitting.
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      The lower mechanical bosses are the ones that I plan to use for my EFI Conversion. Planning on running one large fuel rail to connect both banks since I'm space limited.
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      Starting to look like something!
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      Last edited by BOSSMAN; January 18th, 2014, 04:21 AM.
      Nick Smithberg
      www.smithbergracing.com

      Comment


      • #4

        Re: "One Off" 409 Chevy Induction

        Machining a flat surface for the valley plate to sit against.
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        Scribing the centerline for each pair of ports to be able to reference from above.
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        Here I'm drilling the bolt holes at the correct angle. Also checked and double checked correct spacing for the bolt holes. Thank god for a DRO!
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        Bolt spacing was PERFECT!
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        Just need to spot face the holes now and recess them a little.
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        Nick Smithberg
        www.smithbergracing.com

        Comment


        • #5

          Re: "One Off" 409 Chevy Induction

          Had to make this tool (took 3.5 hours to make) just to do the counterbores. It wasn't an easy task still on a couple holes since the runners get in the way.
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          My setup and goofy angles to do the distributor boss.
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          Had to mill 5/8" off each side of the valley plate and also relieve a few areas just to get it to fit. Just some final machining left to give a little more room.
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          Working on the lower injector location.
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          Ordering materials to do a single large fuel rail for in the center. Holes drilled for 14mm injectors, probably use injectors from a LS / Gen III Chevy.
          Nick Smithberg
          www.smithbergracing.com

          Comment


          • #6

            Re: "One Off" 409 Chevy Induction

            We will be running a crank trigger setup for the EFI so a Plug needs to be used. Knowing these guys it will have to be modified to sit flush on the valley plate instead of making a spacer.
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            Got some injectors here to use for mockup, glad these ones are short! Thanks Scott Clark!
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            Still gonna be a tight squeeze for the single fuel rail.
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            And this will bring you up to the most recent update what I did yesterday. It was a pretty complex operation to get the angles, injector spacing, and bank offset correct but got it done!
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            Nick Smithberg
            www.smithbergracing.com

            Comment


            • #7

              Re: "One Off" 409 Chevy Induction

              Monk should be slobbering in 3...2....

              I really like that the injectors / wiring will be hiding and not kill the vintage vibe. As always, thanks for all the detail!
              Monk likes this.
              Flying south, with a flock of bird dogs.

              Comment


              • #8

                Re: "One Off" 409 Chevy Induction

                amazing work as usual Nick! You continue to prove that there's nothing that can't be done!

                Is the ID of the tubing sufficient for the required fuel flow?
                There's always something new to learn.

                Comment


                • #9

                  Re: "One Off" 409 Chevy Induction

                  amazing work as usual Nick! You continue to prove that there's nothing that can't be done!

                  Is the ID of the tubing sufficient for the required fuel flow?
                  It's a 3/4" ID so that should be sufficient for 650hp on this project. I didn't run any calculations of what is supposed work on this one. It was just a matter of what is the biggest that will physically fit, have enough wall thickness to drill for injectors, and look correct.
                  Nick Smithberg
                  www.smithbergracing.com

                  Comment


                  • #10

                    Re: "One Off" 409 Chevy Induction

                    Jeezus Nick! I can't even cut a 5/16th wide strip of metal straight and you do things like this! Looks awesome as usual.
                    Escaped on a technicality.

                    Comment


                    • #11

                      Re: "One Off" 409 Chevy Induction

                      Looks great! On the c'bore tool, have you ever tried one of the back bore tools, it would allow you
                      to machine the c'bores w/o having to reach around the runners. I've actually used them just for that
                      purpose. They are a little "wonkey" but work quite nicely.

                      Comment


                      • #12

                        Re: "One Off" 409 Chevy Induction

                        Yes I have seen those, my concern was finish and keeping the same depth.
                        Nick Smithberg
                        www.smithbergracing.com

                        Comment


                        • #13

                          Re: "One Off" 409 Chevy Induction

                          Doing some flow testing with the Hilborn attached to the head.
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                          As cast runner with only port match roughed in.
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                          Port Comparison.
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                          Reworked runner.
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                          Line of sight for the injector.
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                          Nick Smithberg
                          www.smithbergracing.com

                          Comment


                          • #14

                            Re: "One Off" 409 Chevy Induction

                            Yes I have seen those, my concern was finish and keeping the same depth.
                            Best I remember finish was OK with lots of WD. Depth is certainly tricky.

                            Comment


                            • #15

                              Re: "One Off" 409 Chevy Induction

                              How 'bout 2 off

                              Great work as usual
                              Thom

                              "The object is to keep your balls on the table and knock everybody else's off..."

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