What horsepower did the Drew Marine 540 make on the dyno?

Peak horsepower was 714 at 6,000 rpm (marked with * as peak), with peak torque of 684 lb-ft at 4,500 rpm.

What are the bore and stroke of the 540 Ford engine?

Bore is 4.500 and stroke is 4.225, giving 537.6 cubic inches with a 10.50:1 compression ratio.

What rods are used in the 540 Ford build?

Production 240 Ford rods forged from 6415 steel, magnafluxed, polished, reconditioned to 2.2750 bore and 6.800 length using a .990 pin, with ARP bolts and a .125 hole drilled in the pin end for oiling.

What camshaft does the article recommend?

Drew Backlund favors UltraDyne's roller cam with 290-300 degrees of advertised duration and .700 lift; the spec sheet lists a solid roller cam of 257 to 266 degrees at .050 with .700 lift, used with Crane rollers, Isky springs and retainers, and Smith Brothers pushrods.

What pistons and rings are specified, and how are they gapped?

Venolia reverse-dome pistons with a 25cc dish and 15-degree cocked squench, set at .0080 clearance measured 1.100 down from the oil ring, with Childs & Albert zero-gap rings — top ring gapped at .020, assembled with ATF rather than engine oil.

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Drew Marine 540 Big Block Ford Build & Dyno Specs - Hot Boat April 2001

Drew Marine 540 Ford dyno test engine specifications and rotating-assembly photos

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Spec sheet and parts photos for a 540 cu in Ford stroker: 4.500 bore x 4.225 stroke, 10.5:1 CR, Durocast crank, Venolia pistons, roller cam .700 lift, plus hp/torque dyno table.

AI caption October 2006 · Photo 2 of 13

This is page 2 of a Hot Boat magazine article (April 2001, page 98) by/about Drew Backlund covering the build of a Drew Marine 540 cubic-inch big block Ford marine engine. The text details the rotating assembly: a Durocast crank, prepped 240 Ford connecting rods (forged 6415 steel, reconditioned to 2.2750 bore and 6.800 length with .990 pins and ARP bolts), Venolia reverse-dome pistons with 25cc dish set at .0080 clearance, Childs & Albert zero-gap rings gapped at .020, and ACL bearings. Bore and stroke are 4.500 x 4.225 for 537.6 CID and a 10.5:1 compression ratio with 75-77cc chambers. Four photos show the rotating assembly, a 460 Ford crank comparison, stock vs. prepped 240 rods, and the valvetrain (UltraDyne roller cam with 290-300 degrees advertised duration and .700 lift, Crane rollers, Isky springs, Smith Brothers pushrods). A full dyno test specification table lists rod ratio (1.61), 38 degrees total timing, 2-1/4-inch primaries into 4-inch collectors, SVO single-plane intake, 950 CFM carburetor, 1.80 rockers, and 2.190/1.800 valves. A dyno chart shows horsepower and torque from 2,000 to 8,000 rpm, peaking at 714 hp at 6,000 rpm and 684 lb-ft at 4,500 rpm.

This document covers 2001, which may differ from this 1996 Ford Aspire.

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Frequently asked questions

What horsepower did the Drew Marine 540 make on the dyno?: Peak horsepower was 714 at 6,000 rpm (marked with * as peak), with peak torque of 684 lb-ft at 4,500 rpm.
What are the bore and stroke of the 540 Ford engine?: Bore is 4.500 and stroke is 4.225, giving 537.6 cubic inches with a 10.50:1 compression ratio.
What rods are used in the 540 Ford build?: Production 240 Ford rods forged from 6415 steel, magnafluxed, polished, reconditioned to 2.2750 bore and 6.800 length using a .990 pin, with ARP bolts and a .125 hole drilled in the pin end for oiling.
What camshaft does the article recommend?: Drew Backlund favors UltraDyne's roller cam with 290-300 degrees of advertised duration and .700 lift; the spec sheet lists a solid roller cam of 257 to 266 degrees at .050 with .700 lift, used with Crane rollers, Isky springs and retainers, and Smith Brothers pushrods.
What pistons and rings are specified, and how are they gapped?: Venolia reverse-dome pistons with a 25cc dish and 15-degree cocked squench, set at .0080 clearance measured 1.100 down from the oil ring, with Childs & Albert zero-gap rings — top ring gapped at .020, assembled with ATF rather than engine oil.