Who's flycut stock pistons for 2.02 intake valves?

jmx2 · 09-04-2001, 10:13 PM

I'm going to have to do this very soon...and I have really no way to pull the shortblock out of the car. I know isky makes a flycutting tool, and I also know somepeople just use a dremmel (!).

Anybody done it either way with the engine in the car? I'm thinking its gonna be a fairly time consuming process masking off all holes in the shortblock and test bolting the heads down constantly.

Jon
'88GT

Unit 5302 · 09-04-2001, 10:28 PM

What heads/cam combo are you planning on running?

andy669 · 09-04-2001, 10:29 PM

i have done it with a dremel with the motor still in the car, but that has been about 9 years ago. I cant remember exactly how we did it. What cam are you running? It might be worth bolting together and checking before you do it. Someone smart here will be able to tell you at what degree of engine rotation that the valves will be closest to the piston. When you get it to that point, push down on the retainer and measure how much it moves with a dial indicator. Thats what i would do.
andy

------------------
3 Black 94 GT Vert. AODE/TKO conversion, 3:73's, ported X-305's, GT40 manifolds, 75mm TB, 30lbers, PMS, 300 horse Top Gun wet kit, and all the other little stuff

jmx2 · 09-04-2001, 10:57 PM

Unit, I've already got AFR 185 heads, systemax intake, and a custom 220/224 .548/.548 112lsa cam all sitting here just waiting for me to install. The heads have large valves though, so flycutting will be nessisary. Once all thats on, the blower or turbo will be going on. I've already converted the car to mass air flow.

andy669, I'll definitly be claying it before I start grinding on anything, but with that lift and the 2.02 intake valve, I'm 99% certain its gonna have issues.

So far I have this link which shows how to do it, I'm just curious if I'm crazy for trying it. http://www.fordmuscle.com/archives/1...ov/index.shtml

I wont mention what lift/duration I can run on an LS1 without flycutting

(just kidding!)

Jon
'88 GT
'00 SS

Unit 5302 · 09-04-2001, 10:59 PM

It's also easy to put a light cover of clay on the top of the piston, bolt the cylinder heads down and rotate the crank over a couple turns if you think you'll be close. The valves will leave an imprint in the clay.

Some 2.02" heads do not require flycutting. Like the TFS TW aluminums. I believe they can run up to .540 lift. That's basically an E303 (Crane 2040) with 1.7's.

Without fly cutting. The stock 88GT had valve reliefs in the pistons to help with that, unlike the flat top 86 hypers.

Unit 5302 · 09-04-2001, 11:00 PM

Looks like you beat me to the reply. Yeah, I don't see that combo having clearance.

As far as flycutting, not much I can help you with. I've never done it.

Sorry.

jmx2 · 09-04-2001, 11:06 PM

I'd like to also take this time to say that HOUSTON PERFORMANCE sold me this combo. I called and told them I have a stock fox body, and will be doing forced induction. I wanted heads/cam/intake that I could bolt right on and hit around 300rwhp.

I get all this stuff finally (took nearly 5 weeks to get all the stuff as they seem to forget to check on things), and then I find out I cant use the dang parts on my stock shortblock without piston modification.

I was a bit annoyed....they made no mention of this over the phone when they were taking my money. *sigh*. Oh well, it'll rock when it all works, just wish they'd told me I wont be able to bolt this stuff on and go.

When I called to confront them about it, the guy on the phone replied "oh..uhm...er...yeah, you're gonna wanna check the clearance, but it *should* work." I asked specifically if people have run my cam and heads on stock pistons with no modifications and he replied "yes, several have I beleive. Just double check it".

Nice action. I wont be using them again sadly...

Five0 · 09-04-2001, 11:23 PM

I have a similar cam and rockers and canfield heads and mine did not clear. I had to have the car towed up to a shop that does fly cutting. They used a canfield head and a tool that went in to the valve hole and cuts the pistons. It cost me about $200.00 to have it done.

------------------
James Cox
nochevy@hotmail.com
1991 Mustang LX
No times with 347 stroker yet.

Five0 · 09-04-2001, 11:25 PM

BTW: I was told my cam would clear also, so don't feel too bad.

------------------
James Cox
nochevy@hotmail.com
1991 Mustang LX
No times with 347 stroker yet.

Rick 91GT · 09-05-2001, 07:59 AM

I fly cut them while they were in the block, but the motor was on the stand. I packed heavy grase around the bore so no shavings made it that far, and I used the fixture below that we made, it is a stock E7 head cut, I used the 4 head bolts to attach it to the block, I brazed cutters on a stock valve and indexed the blade out to act like a 2.05" valve, I used a dial indicator to set the depth. I did have to grind away in the head to allow the valve to travel far enough up in the chamber to bolt the head flush against the block.

Total Engine Airflow also rents a device to do basically what I did for $50 I believe.

Here this may give you some idea's!

------------------
Check Out My Site 91GT,Holley SysteMAX II Kit-Heads 2.02" x 1.60" port matched to a 1262,Anderson N-61,24#,76mm C&L,Full MAC, No A/C or PS or emissions, 12" K&N Filter,RNH PERFORMANCE Ram Air,Ron Davis Radiator,Full Suspension, SPEC stage III clutch, Lakewood SFI bell, S&W 8pt "X" brace,JAZ seats,3:73's,Welds..etc,4:30's and 31 splines coming very soon!
<B>12.16 @ 113.5, 1.78 60ft..no traction in the 90 degree

[This message has been edited by Rick 91GT (edited 09-05-2001).]

09-04-2001, 10:13 PM	#1
jmx2 Registered Member Join Date: Sep 2000 Posts: 26	Who's flycut stock pistons for 2.02 intake valves? I'm going to have to do this very soon...and I have really no way to pull the shortblock out of the car. I know isky makes a flycutting tool, and I also know somepeople just use a dremmel (!). Anybody done it either way with the engine in the car? I'm thinking its gonna be a fairly time consuming process masking off all holes in the shortblock and test bolting the heads down constantly. Jon '88GT

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09-04-2001, 10:28 PM	#2
Unit 5302 Registered Member Join Date: May 1999 Posts: 5,246	What heads/cam combo are you planning on running?

09-04-2001, 10:29 PM	#3
andy669 Registered Member Join Date: Jan 2001 Location: Moline Il Posts: 901	i have done it with a dremel with the motor still in the car, but that has been about 9 years ago. I cant remember exactly how we did it. What cam are you running? It might be worth bolting together and checking before you do it. Someone smart here will be able to tell you at what degree of engine rotation that the valves will be closest to the piston. When you get it to that point, push down on the retainer and measure how much it moves with a dial indicator. Thats what i would do. andy ------------------ 3 Black 94 GT Vert. AODE/TKO conversion, 3:73's, ported X-305's, GT40 manifolds, 75mm TB, 30lbers, PMS, 300 horse Top Gun wet kit, and all the other little stuff

09-04-2001, 10:57 PM	#4
jmx2 Registered Member Join Date: Sep 2000 Posts: 26	Unit, I've already got AFR 185 heads, systemax intake, and a custom 220/224 .548/.548 112lsa cam all sitting here just waiting for me to install. The heads have large valves though, so flycutting will be nessisary. Once all thats on, the blower or turbo will be going on. I've already converted the car to mass air flow. andy669, I'll definitly be claying it before I start grinding on anything, but with that lift and the 2.02 intake valve, I'm 99% certain its gonna have issues. So far I have this link which shows how to do it, I'm just curious if I'm crazy for trying it. http://www.fordmuscle.com/archives/1...ov/index.shtml I wont mention what lift/duration I can run on an LS1 without flycutting (just kidding!) Jon '88 GT '00 SS

09-04-2001, 10:59 PM	#5
Unit 5302 Registered Member Join Date: May 1999 Posts: 5,246	It's also easy to put a light cover of clay on the top of the piston, bolt the cylinder heads down and rotate the crank over a couple turns if you think you'll be close. The valves will leave an imprint in the clay. Some 2.02" heads do not require flycutting. Like the TFS TW aluminums. I believe they can run up to .540 lift. That's basically an E303 (Crane 2040) with 1.7's. Without fly cutting. The stock 88GT had valve reliefs in the pistons to help with that, unlike the flat top 86 hypers.

09-04-2001, 11:00 PM	#6
Unit 5302 Registered Member Join Date: May 1999 Posts: 5,246	Looks like you beat me to the reply. Yeah, I don't see that combo having clearance. As far as flycutting, not much I can help you with. I've never done it. Sorry.

09-04-2001, 11:06 PM	#7
jmx2 Registered Member Join Date: Sep 2000 Posts: 26	I'd like to also take this time to say that HOUSTON PERFORMANCE sold me this combo. I called and told them I have a stock fox body, and will be doing forced induction. I wanted heads/cam/intake that I could bolt right on and hit around 300rwhp. I get all this stuff finally (took nearly 5 weeks to get all the stuff as they seem to forget to check on things), and then I find out I cant use the dang parts on my stock shortblock without piston modification. I was a bit annoyed....they made no mention of this over the phone when they were taking my money. sigh. Oh well, it'll rock when it all works, just wish they'd told me I wont be able to bolt this stuff on and go. When I called to confront them about it, the guy on the phone replied "oh..uhm...er...yeah, you're gonna wanna check the clearance, but it should work." I asked specifically if people have run my cam and heads on stock pistons with no modifications and he replied "yes, several have I beleive. Just double check it". Nice action. I wont be using them again sadly...

09-04-2001, 11:23 PM	#8
Five0 Registered Member Join Date: Apr 2000 Location: middleburg, fl, usa Posts: 1,134	I have a similar cam and rockers and canfield heads and mine did not clear. I had to have the car towed up to a shop that does fly cutting. They used a canfield head and a tool that went in to the valve hole and cuts the pistons. It cost me about $200.00 to have it done. ------------------ James Cox nochevy@hotmail.com 1991 Mustang LX No times with 347 stroker yet.

09-04-2001, 11:25 PM	#9
Five0 Registered Member Join Date: Apr 2000 Location: middleburg, fl, usa Posts: 1,134	BTW: I was told my cam would clear also, so don't feel too bad. ------------------ James Cox nochevy@hotmail.com 1991 Mustang LX No times with 347 stroker yet.

09-05-2001, 07:59 AM	#10
Rick 91GT Procharged! Join Date: May 1999 Location: Hanover, PA Posts: 1,539	I fly cut them while they were in the block, but the motor was on the stand. I packed heavy grase around the bore so no shavings made it that far, and I used the fixture below that we made, it is a stock E7 head cut, I used the 4 head bolts to attach it to the block, I brazed cutters on a stock valve and indexed the blade out to act like a 2.05" valve, I used a dial indicator to set the depth. I did have to grind away in the head to allow the valve to travel far enough up in the chamber to bolt the head flush against the block. Total Engine Airflow also rents a device to do basically what I did for $50 I believe. Here this may give you some idea's! ------------------ Check Out My Site 91GT,Holley SysteMAX II Kit-Heads 2.02" x 1.60" port matched to a 1262,Anderson N-61,24#,76mm C&L,Full MAC, No A/C or PS or emissions, 12" K&N Filter,RNH PERFORMANCE Ram Air,Ron Davis Radiator,Full Suspension, SPEC stage III clutch, Lakewood SFI bell, S&W 8pt "X" brace,JAZ seats,3:73's,Welds..etc,4:30's and 31 splines coming very soon! <B>12.16 @ 113.5, 1.78 60ft..no traction in the 90 degree [This message has been edited by Rick 91GT (edited 09-05-2001).]