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Installing the Shafiroff 509 Engine into a 1961 Bel Air - Bubbletop 509

Backing up a stout 565hp Shafiroff engine meant using hefty drivetrain components to avert certain disaster

Liz Miles Jan 1, 2015
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What a 500ci Caddy engine was doing in this ’61 Bel Air, we don’t know for sure. It did sound impressive, but we were after something even more exotic. The factory option list could have included the unique and distinctive 409ci W-block—an absolute icon. The famous W valve covers under the hood can be recognized from a mile away. And with the Beach Boys song “409” playing on the PA at most any given classic car show, it’s certain the first big-block will forever be remembered.

In 1961, the 409 would have scored 360 hp on the dyno test. Not much by today’s standards for a fullsize passenger car; however, this engine would be right at home between the front fenders. With performance parts selection for the 409 scarce, the easy solution would be to drop in a Gen I or LS-platform small-block or a traditional big-block. We opted for something a little more creative. We contacted Shafiroff Racing and were stirred by their 509. Turns out they got the bright idea to create a high-performance 409-inspired big-block that will outlast the original. They start with a specially made block from World Castings that accepts a variety of standard big-block parts and 409 peripherals, including the iconic cylinder heads. From there, they ended up with a 565hp 509.

Our job was to mate this masterpiece with a healthy transmission and all the accessories that make a car go. This special engine uses some atypical parts because of its hybrid composition. We sought out these parts to mate with both the engine and the Bel Air. It wasn’t exactly all bolt-in, but with the use of a grinder and a MIG welder, you can get the job done.

Shafiroff 509 2/23

The Shafiroff 509: What’s Inside

  • World/BMP 409 aluminum block w/ steel billet caps
  • Eagle 4340 4.250-inch stroke steel crank
  • Eagle 4340 6.385-inch H-beam steel rods
  • Clevite 77 “H” series main and rod bearings
  • Custom Diamond 10.25:1 aluminum pistons w/ coated skirts
  • Total Seal plasma moly ring set
  • COMP custom hydraulic roller cam
  • Street Performance retrofit hydraulic roller lifters
  • Cloyes billet true roller timing set w/ Torrington bearing
  • Edelbrock 409 aluminum heads w/ SSRE port modifications
  • Custom stainless steel 2.25/1.75 valves
  • COMP Cams 1.530-inch roller springs w/ steel retainers
  • ARP custom aluminum block design head stud kit
  • COMP Cams 1.7 Ultra Pro Magnum roller rockers
  • Chrome-moly one-piece 0.080-inch wall 3/8-inch OD pushrods
  • Cometic MLS head gaskets
  • Edelbrock RPM dual-quad large port intake
  • SSRE/Moroso custom stroker oil pan w/ windage tray
  • Moroso race-prepped oil pump w/ TIG-welded HD pickup
  • Polished aluminum front cover w/ billet timing pointer
  • Hi-Performance degreed harmonic balancer
  • Custom cast-aluminum valve covers w/ polished fins and logo
  • New Shafiroff Racing engraved and painted 509 logo
  • Edelbrock vintage finish 600-cfm dual carbs w/ SSRE mods
  • Edelbrock progressive throttle linkage
  • MSD Ready to Run Billet Distributor w/ custom machining
  • Moroso custom wires w/ looms
  • Shafiorff 509 assembled and dyno-tuned: $21,950

1961 Chevrolet Bel Air 3/23

01. First up, we had to get that old Caddy engine and TH400 out. The 509 replacement is a significant investment, so taking care of the old parts to resell them is highly recommended.

509 Engine 1 4/23
509 Engine 2 5/23

02-03. Fitting the 509 engine to the chassis was simple with Classic Industries frame mounts (PN B1726) and Energy Suspension engine mounts.

Arp Flexplate Bolts 6/23

04. Before dropping the 509 Shafiroff mill into place, there were some final things to take care of. We installed and torqued down the flexplate using ARP flexplate bolts and assembly lubricant.

Castings Block 7/23

05. This World Castings block accepts a 409-stlye water pump and this attractive accessory drive kit from Lamar Walden Automotive. We installed these parts before putting the engine into place.

Engine Mount Spacers 8/23

06. To the novice this step can be intimidating, but without a transmission attached the engine slides in between the perches nicely. This is the step where we realized we would need to use the spacers that came with the engine mounts.

Energy Suspension Mount 9/23

07. We slipped the transmission, with the Energy Suspension mount attached, onto the engine to begin modifications to the transmission crossmember. The X-frame narrows as it reaches the center of the vehicle and a longer engine/transmission combination requires shortening the crossmember.

Modified Transmission Crossmember 10/23

08. To make our modified transmission crossmember look nice and to add protection from rust, we used Eastwood Extreme Chassis Black to recoat it.

Inland Empire Driveshaft 11/23

09. The Inland Empire driveshaft passes through their IE210527XS carrier bearing.

Collector Headers 12/23

10. In went the set of Doug’s 2-inch primary and 3.5-inch collector headers, which mate to the Muffler Man custom-built oval exhaust tubing.

Custom Us Radiator 13/23

11. To ensure the big 509 kept cool, we installed the custom US Radiator crossflow radiator into place. Due to the size of the radiator, we needed to trim small sections from each side of the core support.

Power Steeing Lines 14/23

12. With the main components installed, we went to Mesa Hose for their custom-built power steering lines.

Remote Power Steering Fluid Reservoir 15/23

13. The Classic Performance Products remote power steering fluid reservoir was plumbed in as well.

Mechanical Fuel Pump 16/23

14. The Aeromotive mechanical fuel pump got similar treatment with fuel line.

Edelbock Carburetors 17/23

15. Using a 1/4-inch rod, we fabricated the linkage to mate the dual Edelbrock carburetors to the stock throttle pedal assembly.

Transmission Shifter 18/23

16. Lastly, we hooked up the transmission shifter. We used a Kugel Komponents transmission shift arm connection kit.

Splined Post 19/23

17. The bracket is then clamped to the splined post using a pinch bolt.

Rod Cut Point 20/23

18. Before marking our cut point on the rod, we bent it to line up with the shift arm, then cut to fit.

Upper Pivot 21/23

19. The upper pivot connects to the shift arm on the steering column assembly.


Transmission
Stay tuned for an in-depth build story on the Gearstar Level 4 4L80E transmission, which is capable of handling up to 800 horsepower and 700 lb-ft of torque. We also installed a COMPUSHIFT II controller from HGM Automotive Electronics that can operate a wide variety of functions, ranging from automatic shifting, paddle shifting, and torque converter lockup. For more exotic setups, a MAP sensor can also be connected for boosted combinations.

Compu Shift 22/23
Gearstar Level 4 Transmission 23/23

Sources

Classic Industries
Huntington Beach, CA 92648
800-854-1280
www.classicindustries.com
Automotive Racing Products
Ventura , CA 93003
800-826-3045
www.arp-bolts.com
Gearstar Performance Transmissions
Akron, 44308
330-434-5216
www.gearstar.net
Energy Suspension
San Clemente, 92673
888-913-6374
http://www.energysuspension.com
Classic Performance Products
Placentia, CA 92870
800-830-1724
www.classicperform.com
Summit Racing
Akron, OH
800-230-3030
SummitRacing.com
HGM
Torrance, CA 90505
310-787-9260
www.hgmelectronics.com
Aeromotive
Lenexa, KS 66214
913-647-7300
http://www.aeromotiveinc.com
Eastwood Company
Pottstown, PA 19464
800-343-9353
http://www.eastwood.com
Shafiroff Racing Engines & Components
Bohemia, NY 11716
800-295-7142
http://www.shafiroff.com
US Radiator
Vernon, CA 90058
323-826-0965
http://www.usradiator.com/
Kugel Komponents
La Habra, CA
562-691-7006
www.kugelkomponents.com
Lamar Walden Automotive
Doraville, GA 30340
770-449-0315
www.lamarwaldenautomotive.com
Muffler Man
714.524.7818
www.ocmufflerman.com
Doug's Headers
Anaheim, CA 92801
714-502-0286
http://www.pertronix.com/prod/ex/dougs/
Inland Empire Driveline Service
800-800-0109
iedls.com
Mesa Hose Inc.
mesahose.com
World Castings
Sterling Heights, MI 48312
(810) 939-9628
www.worldcastings.com

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