The influence of Mahle F1 piston technology can be seen filtering down to their high-performance street offerings. Coatings, plus thinner and lighter lower-tension rings, along with strut and skirt technology inherited from F1, give them the advantage.
As good as all the gas dynamics of these heads were, it was still short of the sum total. Other options could make a big difference, especially if you intend to use them with a hydraulic roller cam. The valves, springs, and retainers we used have been selected to enhance the rpm capability of the heads without going to a spring as heavy as would normally be used. For instance, the valves had an 8mm stem (a little under 5/16) with a lightweight head. This chops the weight of the intake valve from typically 129 grams to 105 grams with a commensurate save taking place on the exhaust. The valvesprings used for these heads are high-dollar items and also present a performance advantage. For our 408, we are going to need a lot of valve lift. To make a stable valvetrain, the spring must have low mass and a high natural resonant frequency. The AFR spring has both. It weighs a scant 92 grams (typical is 110) and delivers 160 lbs on the seat, and 424 lbs at .600-inch valve lift. Because it is a much smaller diameter than most springs, it needs only a small retainer. This weighs a slim 17.5 grams, as opposed to a typical retainer mass of 33.5 grams. All this attention to detail chops a worthwhile amount of mass out of one of the most mass-critical areas of the valvetrain. AFR's efforts in this direction mean the heads are ideally suited to hydraulic roller cams, and to high-lift solid street rollers-the latter is just what we are going to use.
Note the finer-than-average finish in the combustion chamber of these AFR heads. This is the result of a CNC programming technique that is far from universal among entry-level CNC heads.
Cam Selection
Probably the two top reasons why street engines use a hydraulic roller are the zero-service factor and the quiet operation. What this has done for many hot rodders is exclude the solid street roller from consideration. We have run COMP's solid street rollers for many years; our longest one in service has over 80,000 miles on it, and has yet to need a lash adjustment. Also, by making the lash adjustments with care, the valvetrain is far from noisy. The sound is more like a purr, and is far from objectionable. This is being brought up because a solid street roller was a more appropriate choice; let's look at this 408's requirement. First, it has a lot of inches, so it will need to have a high-lift valvetrain. Secondly, there is enough airflow through the heads to make power up to 7,000 rpm. This means we have to deal with two contradictory situations: high lift and high rpm. Added to that, we needed a long and reliable service life. A COMP Xtreme Energy street roller takes care of that. The profiles chosen were 286XSR for the intake, and 292XSR for the exhaust. These profiles are 248 degrees and 254 degrees for the intake and exhaust respectively. With COMP's 1.65:1 rocker (PN 1006) on the intake and 1.5:1 (PN 1004) on the exhaust, net valve lift after lash was .620-inch and .588-inch.
While the coarse stepped finish in the intake runner has almost no effect on airflow compared to a fine finish, the coarse finish does help break up fuel rivulets for a more combustible mixture.
Induction
The intent is to test two intakes. First, we wanted to see how well an Edelbrock Air-Gap Performer RPM fared on an engine with a projected output of over 520 hp. Experience has shown that on engines in the 300 to 500hp range, this manifold really delivers. Some of our previous testing has also shown that at about 530 hp, it appears to be approaching a limit. But testing on our 408 should better define its already well-appreciated attributes for producing a really strong low end with what is, for a two-plane intake, a very creditable top end. Next on the list to test is a Holley Strip Dominator. This is a manifold which seems to be short on credit for its good power capabilities. On engines capable of 500 or more horsepower, our previous experience has shown it gets the job done in style. With the hot spec of this 408, it seemed like a good idea to reacquaint ourselves with the Strip Dominator's power potential. Both manifolds were checked for a port match. Both aligned pretty well, so it was decided that we would run both intakes in out-of-the-box form.
For carburetion, we had three custom-built Holley carbs. These were carbs that had calibrations specifically for a big-cam 400ci engine. T&L has these built and calibrated for their engines by a Cup Car carburetion specialist. When checked on the flow bench, these carbs (a 750 HP series, a 750 HP with an 850 baseplate, and an 850 with a milled choke horn and some airflow work) delivered 803, 901, and 932 cfm respectively.
Some subtle port relocation and less than subtle port bias toward the cylinder wall side has resulted in a strong flow from the AFR Eliminator exhaust ports.
Spark Generation
For ignition, we used a Pertronix HEI-style distributor with vacuum advance. This was equipped with the lightest springs for the mechanical advance and fed the spark to the plugs via ACCEL 8.8mm plug cables. So why the vacuum advance? With this coupled to manifold vacuum (not the ported vacuum source) we were able to get the motor much more street friendly. Not only did the vacuum advance allow us to get a better and smoother idle, but also it consumed less fuel at idle and part throttle cruise.
Dyno Time
As is often the case, our project engine was run on T&L's dyno in Stanfield, North Carolina. After a one-hour break-in, the oil filter was removed and cut open for a particulate examination. This delivered a clean bill of health, so a new filter was installed and oil was added. The valve lash was given a final check and we were ready to go.
Our main push was to see if we could make 600 hp, and with only 6 hours of dyno time available to us, we did not spend too much time with the Edelbrock Air-Gap Performer RPM tests. The point was more to see what the "bulk" difference might be between the two-plane Performer and the single-plane Holley Strip Dominator. Going in, it was already known that this combination would need a large cfm of carburetion. At the same time, we did not want to compromise driveability, so we chose to run the Holley 750 equipped with the 850 baseplate. With its measured 900-cfm capability, this looked to be a good compromise on what had to be a one-shot deal.
A section through the AFR intake port reveals the floor has a lot less of a "ski jump" than most of its contemporaries.
The custom calibration on the carb proved to be right on the money, as any jet change up or down lost output. The results are in the chart on p. 92. Unless you are familiar with this sort of result, these numbers are going to take a little explaining for the true picture to be more clearly seen. First, note that the numbers are all rounded to the nearest whole lb-ft or hp. The reality is that this engine missed the 550hp mark by just 1.4 hp. That's a very creditable number for a two-plane intake. But look at the peak torque. That is only about 510 lb-ft. Normally, this would be somewhat higher, but because the peak torque is at relatively high rpm, the manifold is already pushed near its limit in terms of best airflow per revolution of the engine. At the peak torque figures, this combo is already well over the 500hp mark that Edelbrock envisaged would be about the limit of its use. What we have here is an example of a subtle parts mismatch. The demand from big cubes and high rpm is being effectively communicated, via a set of highly effective heads, to the intake manifold and carb. But as the big demand from the cubes/rpm/heads combo is increasing, the flow capability of the intake/carb combo is close to being maxed out, even at 5,000 rpm. Result: Because peak torque wants to occur so far up the rpm range on this big-inch motor, the peak torque value is being compromised by lack of sufficient airflow. Don't get me wrong here, the Edelbrock Air-Gap Performer is a great manifold. If, twenty years ago, you had asked a pro engine builder whether a two-plane intake could be made to support even 500 hp, the answer would have been, "not a chance." If we want to see that 5 to 10 lb-ft of increase, then it's a case of using a cam about 10-degrees shorter to move the powerband down into a range more suited to the intake.
So, as good as the Edelbrock two-plane may be, our next tests will show if there is any substance to our theory that this engine just needs more induction capacity.
Single-Plane Test
The first move was to swap out the two-plane intake for the single-plane Holley Dominator. On top of this went the basic mildly-modified 750 with calibrations deemed necessary for the single-plane setup. Although output below 4,500 rpm dropped, this 408 came on strong from there on up. Peak torque went up to 516 lb-ft, and peak hp to 572. That was good, but the carb capacity still looked a little on the weak side for this deep-breathing 408. To check and see if this was so, the 900-cfm 750 (with the 850 baseplate) was installed. Presto! 526 lb-ft and 579 hp. We are starting to look good here. Now working on the assumption that if some is good, and more is better, the 930-cfm (modified 850) might be just right, so it was installed. Result: 534 lb-ft and 587 hp.
At this point, you can see we are closely approaching our target 600 hp. The problem is, we have now used our biggest carb, but as often as not, a 2-inch spacer on an engine of this size can make the carb look bigger, so that was the next move. This resulted in a best of 541 lb-ft and 595.4 hp. Seeing as our 600hp target was so close, our next move would have been to do a little stagger jetting and change the oil for a good synthetic. That would have almost certainly given us the 600 hp we were looking for, but time was against us.
It's worth looking at our graph comparing the output with the two-plane against the output with the single-plane. In round terms, the Air-Gap Performer produced 45 lb-ft more down low, whereas the Strip Dominator produced 45 hp more at the top end. As can be seen from the graph, the crossover point was a shade over 4,500 rpm. As far as the valvetrain went, this COMP solid street roller ran like a 595hp Swiss watch at 6,800 rpm, and valvetrain noise at idle for our diligently lashed system was barely any more than a typical high-performance hydraulic. As for the AFR heads, they proved to be capable of feeding the 408 inches produced by the K1 crank and rods, and Mahle pistons.
At the end of the day, it has to be said that over 540 lb-ft and nearly 600 hp from a bolt-together engine running on pump gas is nothing to sneeze at. Of course, all these great results are academic if the cost of producing them is out of sight. All this comes in at a reasonable budget: T&L offers a turnkey replica of this engine complete with dyno sheet for less than $6,750, and that's well short of the big-block territory that a 600hp pump-gas friendly engine normally requires.
Our swirl and flow tests were conducted on this SuperFlow flow bench right after its calibration was checked and verified. | 
On the left is a conventional spring and retainer. On the right is the spring and retainer used by AFR. The combination of valve, spring, and retainer cuts mass at the valve by 16 percent. | 
The 8mm lightweight valves in the AFR heads are a big advantage when used with a hydraulic roller. |
COMP makes great hydraulic roller cams, but that has tended to leave us overlooking their solid street rollers. These have a long life, low noise, and low maintenance. | 
For rockers, we used COMP's 1.65 for the intake, and 1.5 for the exhaust. High intake lift is vital to get good results from a stroker motor. | 
Positive results with the Edelbrock Air-Gap Performer RPM are the norm, so this manifold was chosen for the two-plane test with our 408. |
We have had several Cup Car engine builders say what good results they have had with Holley's Strip Dominator on their own motors. This prompted us to revisit this single-plane race intake. | 
Here's our 750 body/850 baseplate combo, which delivered 901 cfm when checked on our bench. Except for a polish, the main venturi size was stock. | 
The Pertronix distributor with its high-performance module delivered a strong spark all the way to our 408's 6,800-rpm redline. Note the vacuum advance. This made the engine far more civilized and fuel efficient at part throttle cruise. |
Here is our 408 being readied for they dyno. As standard practice, the motor is primed for about eight minutes to ensure the upper valvetrain is totally lubed. | 
Exhaust is dumped through a set of Hooker 1 3/4-inch headers. Note the wideband O2 sensor in the collector for our Innovate Motorsports air/fuel ratio analyzer. | 
408 Stroker 350 Chevy
Single-Plane vs. Dual-Plane Intake |