Carl Guffey's Modified 2.5 200

[wrechin2]

Carl had the misfortune to have ran over a Wal-mart bag and burned his engine up. While it destroyed #5 and #6, we went through and did some modifications to it and he want me to share them with you guys. His engine started out as a 96 2.5L 200 EFI. While EFI does make more power, it takes alot of $$$$ to make them run. So for economy we converted it to carburetors and removed the EFI along with the HEAVY 40 amp chargine system.We bored #5 and #6 and honed the others. Installed all new pistos due to these engines are noted to loose locator pins in the pistons if ever overheated. </p>

Here is a list of modifications that has been done to the engine.....</p>

1) Has been portedto 1.575 and 2.150 on the transfes and finger/boosters..</p>

2) The heads have been shaved down from 38CC to 34CC</p>

3) The front 1/2 had been shaved .050 and stuffed with epoxy.</p>

4) The oil gear passage has been filled up with epoxy to make all the cylinders equal</p>

5) The block has been cut to reveal the finger/ booster port passages</p>

6) The rough castings have been removed from the block</p>

7) We have upgraded to fiber reeds to help performance and save the engine in case one breaks.</p>

8) Removed the EFI and installed a set of WH-22's. For you merc guys you know how good these are.</p>

9) Removed the 40 amp system and installed a 9amp system. This is easier on the engine to spin up to around 7k which this engine is capable of doing. </p>

</p>

Here are the pictures. They have explainations of what is being done. I hope you all enjoy this. If you have any questions please feel free to ask!!!!!</p>

 

[wrechin2]

Re: Carl Gufey's Modified 2.5 200

I spoke with Carl and he stated this engine idles smooter now than it did when it was EFI and that his fuel economy at cruising speeds has went from 3 MPG to 4.5 MPG. This has added about 42 miles to each tank of gas. This is due to the fact the engine is more efficient and doesn't have to work as hard to maintain cruising speeds. Engine will only get stronger as it gets broken it. It has 4.5 hrs on it now. He has done a few "quick burst" and he can already see it is alot stronger than before. It is alot more responsive at higer rpms. Will have a full report when it is broken in.

 

[jbh3]

Re: Carl Gufey's Modified 2.5 200

VERY interesting, James. Thank you for going to the trouble to make that post. Hope she runs long and strong.

 

[EricM]

Re: Carl Gufey's Modified 2.5 200

Thanks! It is really nice to follow the changes and the reasons for them. Nice job on the engine and the report!!

 

[wrechin2]

Re: Carl Gufey's Modified 2.5 200

It is strong that is for sure. As long as you look at it as a simple moving air, you can understand the mods making a difference. It is making more power and cheaper on fuel. What more could you ask for???LOL!!!

 

[Oldman]

Re: Carl Gufey's Modified 2.5 200

wellll never mind.lol

 

[NRG]

Re: Carl Gufey's Modified 2.5 200

did you make those g4 micarta reeds or buy them ? That material makes great crank bait lips too LOL .. I have a few sheets if you made them and run out of the material to make more

 

[Carl Guffey]

Re: Carl Gufey's Modified 2.5 200

<font size="2">Break-in</font></p>

<font size="2">10/03: James and I launched after dark and put aboutan hour on the motor. Because it was brand new I was really babying it. Before the melt down the EFI would really jump out of the hole, but just seemed to run out of horses at WOT. Even though we were out for a short time, I could notice a small difference in engine response by the time we made it back to the dock. 45 min's run time, 30 miles</font></p>

<font size="2">10/04: Started fairly early Sunday morning finishing the first tank of fuel with two 30 mile runs. I returned to my dock, refueled and made another trip of 70 miles. 3 hrs 15 min's, 160 miles total</font></p>

<font size="2">10/05: I got a late start today, but did get in 73 miles before dark with an additional 2.5 hrs.</font></p>

<font size="2">total miles to date 237, total time 7 hrs.</font></p>

<font size="2">As I have been adding up the break-in time, I have noticed a marked difference in the throttle response. The hole shots are improving and moving through the full range of throttle is becoming increasingly quicker. As James stated earlier the cruising speed fuel mileage is better then I could have hoped for and I am pretty certain that it will increase further once the break-in is complete.</font></p>

<font size="2">One other point of interest, the power band has moved. The EFI was strong from 2000 through 5000 then it slowed and did a slow crawl to 6000. I have been really careful not to over rev on the short bursts but the biggest push seems to be from 3500 on up. I haven't trimmed all the way out and pushed it, but just thinking about it is causing some severe puckerfactor emoDance </font></p>

 

[wrechin2]

Re: Carl Gufey's Modified 2.5 200

Reeds are bought. If I had a CNC machine I could make them. My mill is manual with 2 power feeds.

 

[JDK]

Re: Carl Gufey's Modified 2.5 200

James is the man.. its amazing what he can do.. my motor is purring strong still and has worked great since the day James left it.. would recommend him to anyone

 

[wrechin2]

Re: Carl Gufey's Modified 2.5 200

emoThanks Josh.

 

[Auburnwes]

Re: Carl Gufey's Modified 2.5 200

That's pretty cool seeing it in picture form, it almost makes you forget the great smell of sanding epoxy!

With out a doubt, James has a great attention to detail, and not to mention a heck of a teacher.

Cant wait for the report when your really able to see way she can do!

 

[wrechin2]

Re: Carl Gufey's Modified 2.5 200

This is one of the blocks YOU mill out for me. So don't be modest!!!!!You are a very good student. Soon you will be doing this is your sleep!!

 

[TR20bh]

Re: Carl Gufey's Modified 2.5 200

James,
You're the MAN!! Great info & pics. My motor is running strong. Still need to meet you at the lake & get it set up right. Call me so I can get your # again. My phone died & was so bad I couldn't even get my contacts off it.

 

[wrechin2]

Re: Carl Gufey's Modified 2.5 200

Ben,
Glad to hear your beast is still STRONG. Is it still 1/2 boat lenth out of the hole???? The only difference between this one and yours is the port heights and yours wasn't stuffed with epoxy. I was conservative on yours. My number is 423-304-0930. Talk to you later!

 

[Carl Guffey]

Re: Carl Gufey's Modified 2.5 200

<font size="2">I made another junket this afternoon taking the motor for another 80 miles. Currently it is at 317 miles and 8.5 hrs. This evening's rain put an end to my boat riding. emoBang I hope that tomorrow's weather will dry up and let me finish the brake-in. It is becoming increasingly difficult not to just open the throttle and let it run.</font></p>

<font size="2">The biggest difference today was the ease with which the motor was turning. </font></p>

 

[Guest]

Re: Carl Gufey's Modified 2.5 200

James, the pics are fantastic with the details of what is happening and the reasons for doing the mods. I love to see someone take pride in their work. emoThumbsup emoThumbsup emoThumbsup

 

[wrechin2]

Re: Carl Gufey's Modified 2.5 200

Thanks everyone. I just want for people who are interested in this stuff understand why and how it is done. These are very simple mods that add up to alot. </p>

</p>

Carl, </p>

We may dial it in on saturday if you get the remaining time on it. Then you will be able to see how much more it has on top. I am going out of town tomorrow for a few days but should be back in time.</p>

 

[M GO BLUE]

Re: Carl Gufey's Modified 2.5 200

...Used to think I was a motor BUILDER until I met James....Now realize I am nothing more than a motor ASSEMBLER...I can attest to the knowledge James has for the Merc platform....

 

[wrechin2]

Re: Carl Gufey's Modified 2.5 200

emoThanks Matt. Are you about to get yours together??? Yours is a know 50HP increase, nice thing about the 150's are thereis so much potential!!! It should be a little more with the other mods we done to it. I didn't think I would ever get yours ported with as much as had to be removed!!LOL!!!! REMEBER drain the tank and 93 octane!!!!!!!!!! I can suck out the remainder when you bring it to me. If you start it, use a remote tank.</p>

</p>

I think I will have my monster ready by next week and it is going on Wes's 19' bullet. It should SCREAM!!!!!!! While it is on there we probably will pull his down and modify it. Then I will get my death trap ready for it.</p>