In 1961, Chevrolet introduced the new “W” engine, an enlarged and truly performance version of the 348-CID engine that had gone before. The 409 was the stuff of legends and was available in big bodied Chevys from 1961 through early 1965 when it was replaced by the first of the Mark IV big-blocks. Immortalized by the Beach Boys, who created the song “409” to sing its praises, the 409 was true to the hype of the car offered in a number of horsepower levels and with camshafts and carburetors appropriate for the ponies it generated.
When it debuted on Dec. 17, 1960, the 409 package was available on the Impala SS model with 360 HP (single Carter four-barrel carb). In 1962, Chevy upped the ante with a 380 HP version sporting the same induction system. In addition they offered a 409 HP edition matching the one horsepower per cubic inch effort they delivered in 1957 with their fuel-injected 283 engine. The 409-HP engine wore a dual aluminum four-barrel intake manifold with twin Carter AFB carbs. But the best was still yet to come.
Rough and tumble, this ’61 Chevy will be the host organism for our new 409. Don’t worry, it already looks a lot better than this. Check out the rendering to look into the future.
In 1963, the 409 peaked with the highest horsepower rating it was to achieve, a 425-HP decal adhered to the air cleaner covering the twin Carter carbs, 11.25:1 compression pistons and solid lifter camshaft. Not to overlook those owners uninterested in having to set the valve lash every Saturday morning to ensure the highest rate of tune, a 340-HP engine with a hydraulic cam shaft continued to be offered from 1963 through 1965. There was a 409 for every taste.
For trivia buffs the 409 “W” engine had an even larger displacement and often forgotten race engine cousin that was to catch many a headline starting in 1963 when it was offered as a Regular Production Option (RPO) code. The 427 Z11 engine was to 409 fans what the original 426-Hemi engine was to Mopar 392-CID engine nuts. This 427-CID aluminum engine was a 13.5:1 compression beast that used a two-piece, high-rise aluminum intake manifold and allegedly produced only 430 HP. Clearly a ruse to throw off the competition, only 57 of these rare Z11s were ever built, but they were to cement the 409 legacy in the minds of Chevy racers and speed freaks forever.
The Muscle Car TV 409 shown here takes off where the legend ended in 1965. Today there is a host of new parts and pieces that every 409 fan — and those looking for a new way to motivate their classic Chevy — can appreciate. For the record, the “W” notation referred to the upside down “W” shape noted in the valve cover — amazing but true.
The engine shown here was designed for the “Muscle Car TV Red Sled” project car and uses the latest technology, including aluminum cylinder heads, forged aluminum custom pistons, dual quad aluminum intake with Edelbrock carbs, and lots more. When run on the “Muscle Car TV” dyno, the finished product cranked out peak performance figures of 497 HP and 525 lb.-ft. of torque, which is better than the original rating on the 430-HP Z11 with far better street manners, including the ability to use street fuels instead of the 100-plus-octane race gas needed for the 13.5:1 compression race engine.
As is clearly the case with this 409 engine, some things get better (and nastier) with age.
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- Rough and tumble, this ’61 Chevy will be the host organism for our new 409. Don’t worry, it already looks a lot better than this. Check out the rendering to look into the future.
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- The 409 used for the build-up was a seasoned block selected and prepped by Lamar Automotive. As you can see, he has a wide assortment of “W” engines to pick from.
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- Beginning in 1962, an “X’ was cast into the front of the 409 blocks, as well as 348 truck replacement engine to denote the performance orientation. These are the good ones to start with. Note the screw in freeze plugs.
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- The block was cleaned up and honed prior to installation by Lamar Automotive. The block was carefully checked for cracks, all channels flushed and all threaded holes were cleaned for future bolt insertion. The block was rough honed with 220 and finished with 280-grit to seat the piston rings.
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- Lamar Walden Automotive builds custom forged aluminum pistons for these engines, cutting valve relieve holes when necessary and setting the compressions ratios as requested by customers (in our case 11:1). This is a CNC process that ensures consistency throughout the engine.
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- Note the improvement in quality over the last 45 years; these aluminum pistons are far superior to the original cast units offered by GM and are of the 425-HP GM design. The rings are 5/16-inch thickness (Sealed Power Plasma Poly), and the compression is GM stock using a 6.135-inch long connecting rod.
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- The Eagle Crank was balanced and test fitted to the block before final insertion. Clevite bearings are used for the mains, journals and cam bearings.
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- Lamar Walden developed a special grind hydraulic roller camshaft for the 409 using COMP Cams tech engineers. End play is a problem with these blocks, which often have excessive play and wear down the cam gear quickly. The cam thrust button is pressed into the timing gear cover to set proper play and avoid this problem.
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- Edelbrock offers new Performer RPM aluminum cylinder heads that feature the stock port locations and valve angles. They include a 220cc volume intake port runner and 90cc exhaust ports with hardened spring cups, screw in studs and hardened guide plate. If there was a consistent sore point with 409 engines, it was the lack of guide plates, which allowed valve train instability.
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- What other color than Chevy Engine Orange would you use on a classic engine like this? Note the care given to avoid overspray in areas that don’t need paint. All mating surfaces, such as where the pan meets the block, should be clear of paint or they could leak oil later. The paint is from Duplicolor.
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- This GM oil pump is a high volume unit to ensure oil reaches all critical points within the engine.
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- The oil pan rails were checked for straightness and test fit to the engine. This GM unit matches the original configuration offered for 409 engines of the era. The original canister-type oil filter has been replaced with a modern Trans-Dapt spin-on-style unit.
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- Talk about technology, these 1.7: 1 ratio Magnum roller rockers from COMP Cams are light years from the original slide rockers offered by GM. These rockers were thoroughly lubricated before installation.
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- This cool intake is an Edelbrock Performer RPM air gap. The overall manifold height is 1 5/8 inches taller than the original, and the air gap design separated the runner from the hot engine valley delivering a cooler, denser charge to the port.
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- These Edelbrock 600-CFM Performer carbs are the crowing touch, delivering period style looks and great performance. The metering rod system allows for quick tenability and the progressive throttle linkage is designed to work with their manifold
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- The ignition system was installed using a Malloy coil and distributor as well as Taylor Cable wires and Denso plugs.
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- On the dyno the engine cranked out an amazing 497 HP and 525 lb.-ft. of torque after some significant timing adjustments.
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- This engine is far superior to anything offered by GM in the heyday of the 409. Things like the Doug Thorley ceramic-coated Tri-Y headers are typical of the advancements made in generating excellent power and torque for this streetable engine.
Sources
ARP
Rod bolts, main bolts and accessory kit
800.826.3045
www.arp-bolts.com (http://www NULL.arp-bolts NULL.com/)
COMP Cams
1.7:1 Magnum roller rockers
Hydraulic roller camshaft
800.999.0853
www.compcams.com (http://www NULL.compcams NULL.com/)
Denso Products
Iridium spark plugs
888.96.DENSO
www.densoiridium.com (http://www NULL.densoiridium NULL.com/)
Doug Thorley headers
Ceramic-coated Tri-Y headers
800.347.8664
www.dougthorleyheaders.com (http://www NULL.dougthorleyheaders NULL.com/)
Eagle Specialty Products
Steel 4340 crankshaft
6.125-inch connecting rods
662.796.7373
www.eaglerod.com (http://www NULL.eaglerodcom/)
Edelbrock Corp
Performer RPM cylinder heads
Performer dual quad air gap manifold
Edelbrock 600-CFM carburetors
Aluminum valve covers
Large oval cast air cleaner
Oil filler tube
310.781.2222
www.edelbrock.com (http://www NULL.edelbrock NULL.com/)
Lamar Walden Automotive
Machining and assembly
770.449.0315
www.lamarwaldenautomotive.com (http://www NULL.lamarwaldenautomotive NULL.com/)
Mallory Ignition
Unilite ignition and coil
216.688.8300
www.malloryperformance.com (http://www NULL.malloryperformance NULL.com/)
Stage 8 Locking Fasteners
Header bolt locks
www.stage8.com (http://www NULL.stage8 NULL.com/)
Trans-Dapt
Spin-on oil filter adapter
562.921.0404
www.tdperformance.com (http://www NULL.tdperformance NULL.com/)
Taylor Cable
Spark plug wire set
www.taylorvertex.com (http://www NULL.taylorvertex NULL.com/)
816.765.5011
Tags: 1961 chevrolet, 409 build, Chevy 348, Chevy 409, Chevy W engine, courtney hanson, Edelbrock, horsepower tv, little 409, Mallory Ignition, powerblock tv, red sled, Stage 8 Locking Fastners, Taylor Cable, Trans-Dapt
