1984 SD4 Resurrection

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FieroWanaBe1
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Re: 1984 SD4 Resurrection

Post by FieroWanaBe1 »

I recently acquired, from eBay, a dual 48mm DCOE flange for building my '801 ITB manifold.
I will have to open up the runner ports to 50mm to match my larger throttle bodies.
I want to have an aluminum intake for the final build, but I am thinking I can dyno test with a 3d printed one to confirm it does what I want.
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FieroWanaBe1
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Re: 1984 SD4 Resurrection

Post by FieroWanaBe1 »

While I'm waiting for UPS to unf*ck my shipping of the old head and intake, I went to the block to prepare it for deep cleaning.

I have most of the freeze plugs pulled, but the rear freeze plug is very stiff and will not budge with my drill and pry bar method, I will have to cut it out, its now lodged against the cylinder wall and one of my prybars is bent, and I am currently out of cut off discs for my Dremel. These plugs where very hard and thick compared to the cheap soft steel hones I have encountered previously.

I pulled the 7/16 main studs, to discover that the block was heli-coiled to 7/16-14. This makes perfect sense but is an issue.

I believe factory dukes came with 11mm main cap bolts. The early SD4 blocks, like mine came shipped machined off factory tooling. The build guide instructed to redrill them for the prescribed 1/2" Main studs using a 27/64 Drill for a 1/2-13 tap.

Helicoils in the 7/16-14 thread pitch require a 29/64 drill, 1/32 larger than the proper 1/2-13 tap drill, I don't have any material left to cut 1/2-13 threads.
Using a 1/2-13 helicoil would reqiure a 17/32 drill, I am not so sure I retain adequate material on the main journals at the mating flange for such a large tap size, especially at the bearing retaining tang.

I may be stuck with the 7/16 main studs, which may be adequate, just not what was prescribed by the original build and what is equipped on later SD4 blocks.

I also found a weld repair at the last main saddle, The repair looks well done, and the bearing journal looks great, maybe this was a factory done repair, since the block was purchased new by the owner, or the machine shop messed up something.
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FieroWanaBe1
Posts: 507
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Re: 1984 SD4 Resurrection

Post by FieroWanaBe1 »

The Iron head is with its new owner.

The 2 barrel intake is lost in UPS hell, And I'm out of a fair amount of money for all of it, it seems. the label Purchased through Ebay, and lost by UPS, which makes filing a claim difficult, international support help lines, callback times, and gouging eBay fees, means I owe way over what i receive from the sale for a refund, I'm not too happy.
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FieroWanaBe1
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Re: 1984 SD4 Resurrection

Post by FieroWanaBe1 »

looks like my lost intake has popped up on ebay again.
https://www.ebay.com/itm/325834880620?h ... media=COPY

for whatever reason i cant report it to Ebay.
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FieroWanaBe1
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Re: 1984 SD4 Resurrection

Post by FieroWanaBe1 »

I just sold my centerline wheels, I think they are a bit too heavy.

I am also selling the old header, as it wont have the right flange, and I think the primary size is a little small, for the '801 head.
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FieroWanaBe1
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Re: 1984 SD4 Resurrection

Post by FieroWanaBe1 »

https://www.summitracing.com/parts/uem-ic551ckts030
Looking at pistons.
With 6.25" SBC rods from Speedmaster, I can use these LQ9 flat top pistons w/o reliefs, and shave .015" off the top to make deck clearance 0.000
I would have to ensure the machine shop can get a good bore at 4.030 and the deck height is still in spec at 9.164
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The Dark Side of Will
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Re: 1984 SD4 Resurrection

Post by The Dark Side of Will »

What CR does that give you?
FieroWanaBe1
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Re: 1984 SD4 Resurrection

Post by FieroWanaBe1 »

Pistons as is would be about 9.9 with unmodified 67cc chambers.
9.5 with the pistons machined.
Decking the head would be the prefered method to adjust CR, as Pontiac intended.

The pistons .014-.015 proud of the deck in think may be a little risky. The head gasket is .039 compressed.
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FieroWanaBe1
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Re: 1984 SD4 Resurrection

Post by FieroWanaBe1 »

With the Mercruiser 3.6" crankshaft, and 6.25" SBC rods,
I can use LQ9 stoker pistons:
https://www.summitracing.com/parts/uem-ic552ckts030,

Compression height is spot on to theoretical, 1.114".

I found a '94 MerCruiser crankshaft on ebay for $177 shipped. I will compare it to my 3.25" SD crankshaft, but the seal and bolt flange will be different, since the MerCruiser uses SBC dimensions.


I need to take the block to one of the two machine shops I've been talking to that are taking work, I'll need the final cleaned bore, and final deck height.
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The Dark Side of Will
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Re: 1984 SD4 Resurrection

Post by The Dark Side of Will »

Is mid-high 9's enough? I would have thought you'd want mid-11's or higher.
Is your intended head iron or aluminum?
FieroWanaBe1
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Re: 1984 SD4 Resurrection

Post by FieroWanaBe1 »

My goal is near 11. 9s would be fine if I wanted to go turbo. I dont right now.

A 3.6" stroke will net an 11:1 ratio with the 67cc chamber of my aluminum head.
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FieroWanaBe1
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Re: 1984 SD4 Resurrection

Post by FieroWanaBe1 »

Forged Steel 1059 SD4 crankshaft GM 10027779, 2.250" Mains, 2.100" Rod Ends x 0.952" Wide, 3.25" stroke
vs
Cast Nodular Iron GM 3.0L Industrial Crank GM, made Feb of 92, 2.250" Mains, 2.100" Rod Ends x 1.039" Wide, 3.6" stroke

Looks like in 1999, GM switched to an SBC width rod.
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FieroWanaBe1
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Re: 1984 SD4 Resurrection

Post by FieroWanaBe1 »

I have been on the hunt for the proper lifters for my camshaft. Morel seems to be the only ones that list lifters, The tech at crower couldnt see anything they offered that matched, and Bullet cams are adamant that nothing exists that they have done, At first didn't believe they made my camshaft, but it was verified by serial number.

PONTIAC 4 CYL SUPER DUTY MECHANICAL ROLLER LIFTERS
Set# Pair# BodyD RollD Description Avail
7774 7773 0.842 0.750 PONT 4 CYL SUPER DUTY .842D, U/P, P/O, O/C, +.300 T/B NOW

Howards Cams is local to me and are checking on pricing and availability.
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FieroWanaBe1
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Re: 1984 SD4 Resurrection

Post by FieroWanaBe1 »

Howards Cam will be able to Order the lifters for me. And they are much cheaper than Crowers recommended Pontiac 455 set, which may be too short overall.
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FieroWanaBe1
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Re: 1984 SD4 Resurrection

Post by FieroWanaBe1 »

Nothing great to update, other than piecing together the ECU
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Speeduino based Ocelot, 4 Channel fuel and ignition, now I have to offload my Microsquirt.
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The Dark Side of Will
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Re: 1984 SD4 Resurrection

Post by The Dark Side of Will »

Snazzy!
ericjon262
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Re: 1984 SD4 Resurrection

Post by ericjon262 »

that looks way classier than a microsquirt.
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FieroWanaBe1
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Joined: Sun Mar 11, 2007 11:26 pm

Re: 1984 SD4 Resurrection

Post by FieroWanaBe1 »

ericjon262 wrote: Sat Mar 01, 2025 2:51 am that looks way classier than a microsquirt.
The core MS2 processor for the microsquirt is a little more powerful than the Arduino unit, but the collective brain trust of the Arduino environment closes the gap much more.
From what I see the Ocelot board is pretty nice, but not the most robust, but for the price, pretty hard to beat.
https://wtmtronics.com/product/ocelot/
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FieroWanaBe1
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Re: 1984 SD4 Resurrection

Post by FieroWanaBe1 »

The head has larger, freer-flowing ports, better cooling, and provision for stouter valvetrain components. A forged-steel crankshaft with full counterweighting spins inside the crankcase, and it can be machined to provide a variety of strokes from 2.60 to 4.125 inches. This crank design profited from the lubrication-and-stress analysis expertise of General Motors R&D. According to Callies, it is bulletproof to 10,000 rpm with a 3.25-inch stroke, even with only two-bolt main-bearing caps. The crank is spun by JE forged pis~ons via connecting rods from a Chevrolet small-block.
Keeping the valvetrain together at elevated engine speeds has been more of a problem. The heads are fitted with 2.02-inch-diameter intake valves and 1.60-inch exhaust valves for good breathing, but these components are not light, even though they're made of titanium. They are
actuated by roller rocker arms, special pushrods, and roller lifters-a lot of hardware to be jiggling around at 8000 rpm. Initially, very stiff valve springs were fitted to control these parts, but the results were broken rocker arms and excessive valve wear. These problems have been remedied
by placing springs from a Ford flat-head engine between the roller lifters and the top of the block. These springs keep the lifters and pan of the pushrod mass under control, allowing lighter valve springs. According to Callies, this solution is good to 9600 rpm. Another knotty problem cropped up in the cam-driven gears. The crankshaft of this large four-cylinder engine may not break, but it does bend at high rpm. This phenomenon caused the early, helically cut cam-drive gears to break, even when the cam-gear material was upgraded from aluminum to cast iron to nodular iron. A change to straight-cut teeth eliminated the thrust forces and solved the problem.
From Car and Driver June 1985.

Interesting on the valvetrain, the rev kit is discontinued, interesting tidbit means the springs should be standard and available for the flathead ford. According to Bullet Cams, it would be unnecessary with the correct rocker arm and modern spring. I will probably need to use Stainless BBC rockers for strength with my Solid roller set up, and I will have to design myself a girdle.
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Shaun41178(2)
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Re: 1984 SD4 Resurrection

Post by Shaun41178(2) »

Buy that twin cam super duty over in the mall on poopcocks forum

Do it.
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