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2009 Crew Cab - Stage III Build Begins

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Old 05-06-2016, 07:03 PM
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Default 2009 Crew Cab - Stage III Build Begins

Stage II build was last spring and involved cam, PRC stage 1 heads, and a larger crank pulley to make ~11 psi of boost on my SBE Gen IV 5.3L. The results were a solid 518 hp and laying down a 12.7@109.5 in the quarter at full weight on 31.5 inch factory goodyears. Fast forward to around thanksgiving and it turns out that lifters don't like too much preload (the heads that I thought had 64 cc chambers really had 59 cc chambers from being milled 0.03").

What I thought would be a 2-3 year life span rapidly turned into a 1 year build when I ended up with some piston to valve contact. The truck still drove and acted strong off idle, but had high KR and erratic idle vacuum. When I started digging, I could feel 7 of the 16 lifters were basically solid but luckily none had come apart. The result was valves which had self clearanced pistons crowns...so I pushed up the timeline on stage III:
  • New 377 cubic inch Stage 2 LS3 shortblock from Thompson Motorsports with -11 cc Wiseco forged pistons and forged scat rods and ARP bolts
  • BTR Stage 2 PD blower cam - 227/242 .614"/.592" 122+6 (other cam actually is still fine, just thought it would be small for the new combo)
  • PRC Stage 2.5 243 heads (same heads with new bigger valves and seats shaped)
  • 8 rib drive conversion from LC32 and smoothflow pulleys custom making 8 rib 3.1, 2.9, and 2.75 pulleys and a hub adapter for the Roush
  • Johnson 2110 lifters
  • 5/16 .105 wall (correct length this time) pushrods
  • Maintaining the stock flex fuel pump and 56lb injectors for now, going to see which pulley I can use
  • Keeping 1 7/8 kooks long tubes, but will likely convert the y pipe to a 4" outlet and custom fab a 4" single exhaust...thinking with a 20" magnaflow

All of this should put me at ~10.5:1 compression and start out making 7-8 psi of boost. Goal is to make 600 RWHP. This truck is genuinely my daily driver, and I have already been carpooling with the wife for about a month, so I am more than eager to get this going. Already have the old engine being held in with only a couple bellhousing bolts, just waiting for a good time to yank it out.

Last edited by vettelovralexand; 05-07-2016 at 03:17 PM.
Old 05-07-2016, 12:07 PM
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Wow. I'm sorry to hear about that but this next stage will be aggressive!!

Did you already order the cam? It's more of a square port cam...
Old 05-07-2016, 12:43 PM
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Originally Posted by Vortec350ss
Wow. I'm sorry to hear about that but this next stage will be aggressive!!

Did you already order the cam? It's more of a square port cam...
Yeah, I called and spoke to Brian about a custom spec and he said that for a big truck and factory stall that he would spec it like he would for a square port car. Either way it has the same split to what I have now, and I love the way it drives. If I don't like it, I'll swap it again.
Old 05-08-2016, 07:07 PM
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Anyone had any luck buying a 4 inch over the axle pipe from mbrp or anyone else? I think I could use straight 4 inch pipe and flatten it some to replace the 3 inch outlet on my y pipe and run all the way back to the muffler. From there the muffler and an over axle section is all I need. What are people doing?
Old 05-16-2016, 06:56 PM
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Finally got the engine out of the truck, you can see the valve marks on all 8.




Also got the heads back from being converted to stage 2.5.


Plus I got the PRW water pump and cam from BTR on a cam motion core.

Still waiting on the shortblock, the blower, and the 8 rib setup.
Old 05-16-2016, 08:00 PM
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Got a picture of the new pulley setup.




And I checked installed height with the new valves, with almost all of them right at 1.76". Will need to see if I can get a thinner shim. While they were apart I reassembled one with light springs so I can check PTV. They will both get new springs so that I don't have to check them for another couple years.
Old 05-17-2016, 08:55 AM
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The build is looking awesome. Keep up the good work. We are looking forward to seeing the end result.
Old 05-17-2016, 03:54 PM
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Originally Posted by thompson
The build is looking awesome. Keep up the good work. We are looking forward to seeing the end result.
Thanks! I figure I'll see the short block from you late this month or early next.
Old 05-19-2016, 04:27 PM
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Got the 8 rib drive pulleys today from LC32. They look like very high quality pieces!
Old 05-19-2016, 04:49 PM
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Pretty stuff!


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