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302 Compression challenges |
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RacerJames
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Topic: 302 Compression challengesPosted: 22-November-2025 at 6:30PM |
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I have a small collection of 302 parts that I am experimenting with. One is a D4DE block that I understand is 20 thousandths taller than most other years. It came with D5OE heads which have (I measured) 58 cc chambers.
It also came with some deep dish pistons which I measured and calculated to be 42.35 CC. This combination yields 6.43:1 compression according to the Summit compression calculator. I have to assume this combination was never a factory assembly. I'm debating decking the block 0.020 to get it to the "normal" 302 height, adding flat top pistons and bigger 351W valves and porting it to take advantage of the bigger valves. Then I'll have a 10:1 302 that'll make significantly more power than the current setup. I'm expecting 300hp with the cam I have.
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'73 Torino Stock Car
'71 Mustang Stock Car 351C powered |
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Inkara1
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Posted: 22-November-2025 at 10:29PM |
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6.43:1? That's lower than later iterations of the flathead Ford V8. I can't imagine you're getting much more than a flathead-like 110 horsepower out of that... but you can run pretty much any fuel you can find without pinging. Probably pretty good for a farm or ranch truck.
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1972 Gran Torino station wagon, light blue, 351C 2V, prior owner upgraded to 4V (2V heads), originally had a C4 but prior owner changed to C6 for some reason.
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Rockatansky
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Posted: 23-November-2025 at 4:42AM |
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what is the piston to deck clearance of the short block with the pistons in it now? can you post up a pic of the piston dish, 42+ cc's seems rather extreme even for 1974
Edited by Rockatansky - 23-November-2025 at 5:14AM |
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RacerJames
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Posted: 23-November-2025 at 5:23PM |
Excellent questions. I haven't mocked this motor up yet, so not sure about deck clearance. I assumed 0.025. The dishes are DEEP. about 1/4 inch deep and 2.5 inches in diameter. ![]() |
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'73 Torino Stock Car
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Rockatansky
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Posted: 24-November-2025 at 12:28PM |
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72 RS 351
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Posted: 24-November-2025 at 12:56PM |
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Ditto, the 42cc figure is probably a misprint. Those look kind of typical, I'd guess the dish is around 15cc or so.
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Don
73 Ranchero "Sport 72 front end", floor shift/console, planning EFI 7000 rpm 351 stroker 73 Ranchero GT 351C-4V &4R70W for sale later. 92 Lincoln Mark VII SE GTC, OBDII 347/4R70W |
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RacerJames
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Posted: 24-November-2025 at 11:27PM |
I like the tool, made my own recently and used it to measure the D5 heads. Guess I'll recheck my measurements using the tool. The measurements I took and the math I had the internet do for me: ![]() My mistake was using diameter instead of radius here: Oops. ![]() ![]() Edited by RacerJames - 25-November-2025 at 12:18AM |
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RacerJames
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Posted: 25-November-2025 at 12:01AM |
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Using a more direct measuring tool I get a piston dish of 12cc. Much more reasonable. So my first post corrected for the error: D4DE 302 block that I understand is 20 thousandths taller than most other years. D5OE heads which I measured at 58 cc chambers.
Dish pistons which I measured at 12 cc This combination yields 8.41:1 compression according to the Summit compression calculator. I'm debating decking the block 0.020 to get it to the "normal" 302 height, adding flat top pistons and bigger 351W valves and porting it to take advantage of the bigger valves. Then I'll have a 10:1 302 that'll make more power than the current setup. I'm expecting 300hp with the cam I have. I also have a '68 289 short block with flat top pistons installed. If i use the 58cc D5OE heads on it I calculate 9.82:1 compression. The mid 70s smog heads are not bad if ported properly and used with the right pistons. Edited by RacerJames - 25-November-2025 at 12:16AM |
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Rockatansky
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Posted: 25-November-2025 at 12:04PM |
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i have a feeling you're conflagurating or have gotten bad info that the 351W deck height variation (9.480" for 1969-70 and 9.50" for 1971-96) applies to your 302? i've never heard of the .020" deck height difference applying to the 302 unless it was a print error, and i've also seen the error applied to 351C's as well. it was only the 351W. also FWIW production engines run about .035" deck clearance, simple enough to check and be sure
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RacerJames
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Posted: 27-November-2025 at 1:36AM |
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I've been aware of verified 351W differences for around 35 years. In the early '90s I decked a '79 351W block and the machine shop questioned it until they checked specs. That was a good engine. Other info I've read says that deck clearance is .005 to .015. Deck clearance of .035 makes me think the .020 info might be correct. Trust but verify. After I put in the time to measure this one I'll post my findings here. |
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Rockatansky
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Posted: 27-November-2025 at 3:14AM |
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sounds like a plan
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RacerJames
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Posted: 28-November-2025 at 11:16AM |
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So using a Harbor Freight digital caliper, a machinists ruler and a tape measure (not the end of the tape as those can vary significantly) I get the following:
Deck Height 8.219 Deck to piston at TDC 0.106 Rod length C8OE 5.098 (as a check of my math and tools) So a huge deck clearance, .020 taller deck and large dish equals 7.18:1 compression. No wonder these engines in '75 were slugs.
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72 RS 351
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Posted: 28-November-2025 at 3:33PM |
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I don't know what your real figures are, but that sounds a point or more low. Do remember, the compression is calculated with total of the displacement volume plus chamber, divided by the chamber volume.
So a rough example could be say 1000cc displacement plus 100cc chamber, divided by the 100cc chamber, thus (1000+100)/100= 11 ... or 11:1 compression. Are you adding the chamber volume to the displacement volume before dividing the chamber volume? It's been ages since I looked at 302 dimensions. Most pistons stock would be in the 1.6" or taller range IIRC. So a 5.098" rod is about 5.1" plus a 1.5" stroke half length, the 1.60" guess piston height, I'd think the stack to be around 8.2 or very close. That's where the quench is, what's left, hopefully it's under .050" to the piston top for an efficient explosion.
Edited by 72 RS 351 - 28-November-2025 at 3:43PM |
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Don
73 Ranchero "Sport 72 front end", floor shift/console, planning EFI 7000 rpm 351 stroker 73 Ranchero GT 351C-4V &4R70W for sale later. 92 Lincoln Mark VII SE GTC, OBDII 347/4R70W |
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RacerJames
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Posted: 29-November-2025 at 3:28AM |
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I am as surprised as anyone. I am astounded at the quench being a tenth of an inch. I measured it several times and ensured twice that I actually was at TDC. I was amazed to find that the internet was correct in saying that '73 to '76 302s are 0.020 taller than other years. Deck to piston at TDC 0.106 inches Chamber 58cc Piston dish 12cc Bore 4 inches 8 cylinders And the ones I assumed: Stroke 3" Gasket 0.040 I then used this tool: https://www.summitracing.com/newsandevents/calcsandtools/compression-calculator The tool is accurate when I put in published numbers from Ford. Feel free to test it.
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RacerJames
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Posted: 08-December-2025 at 9:52AM |
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The deck to piston clearance being .106 in this engine I'm considering some 351W pistons.
I measured 1.607 pin height on the pistons pictured above. I have a new set of 351W flat tops which spec at 1.703 pin height. 1.703 - 1.607 =.096 and 1.06 - .096 = .010 below the deck. A reasonable safety margin with a .040 gasket. Before I bore this 302 to accept my .030 over pistons, How will adding a tenth of an inch taller pistons affect the rotating assembly's balance? Has anyone done this? While googling, I found the opposite is a common enough thing that both Scat and Eagle make a crank. I have a worn out (it's already .030 and the pistons are sloppy) '69 351 in the collection. Now I want to build a .060 over 398.
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72 RS 351
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Posted: 08-December-2025 at 12:50PM |
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I would weigh the pistons and expect enough difference to need balancing.
What heads are you using, do you have a decent budget? I have a new set that I stopped planning for a 306 or 347 project, so will sell them at some point. These are a Flowtek 180 made after a GT40X head, which are mild flow, about 235cfm at most. I had new special valve springs installed in them, planning for a custom cam, and the builder(Thumper) had polished them fully in looking for casting issues(china knockoff). So they aren't really ported I expect, just touched on to be sure nothing was wrong. They are supposed to be 58cc chambers.
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Don
73 Ranchero "Sport 72 front end", floor shift/console, planning EFI 7000 rpm 351 stroker 73 Ranchero GT 351C-4V &4R70W for sale later. 92 Lincoln Mark VII SE GTC, OBDII 347/4R70W |
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RacerJames
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Posted: 09-December-2025 at 3:07AM |
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I have a pair of rebuilt original '69 351W heads, but I'd be interested in yours for this build. PM sent
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RacerJames
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Posted: 07-January-2026 at 9:42AM |
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Got a benchtop press for Christmas and built a fixture for pressing piston pins out without piston damage. Also got a set of 60 over pistons for the 399 project. Is static balance enough with the stroker crank, or should I have the assembly dynamically balanced as well? Any recommendations for a good gram scale?
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Rockatansky
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Posted: 08-January-2026 at 3:05PM |
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i'm not saying you can't do it, but i wouldn't even if i had professional quality equipment in good nick available to me. the cost of the learning curve is just too high compared to letting the man with hopefully decades of experience work his magic. modern piston alloys will not survive the loads & pressures involved in pressing the pin into a press fit rod, the the rod furnace is a must! i'm aware there's a way with the right fixture to support the rod and float the piston in the press, but again is it worth the risk? and yes you can do the static balancing yourself & save a couple bones. it's not so much the quality of the scale but the fixture, how it sits on the scale. precision repeatability is the tricky part. dynamic on a complete stroker rotating assy? yeah i'd say that's pretty important, there's a reason they spin it real slow the first time. what alloy are your pistons? Edited by Rockatansky - 08-January-2026 at 3:12PM |
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RacerJames
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Posted: 09-January-2026 at 9:02AM |
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Pistons are Perfect Circle TC 1916. Cast pistons from the late '80s or early '90s.
Most of what I read says to dynamically balance the crank to the rod and piston assemblies using the 28oz imbalance flywheel and harmonic balancer. I plan to have the shop do that. The fixture I made for the press has been tested and works fine. I have a running engine which employed it during its build. So no worries there. Looks like I'll be learning a bit about balancing rods as I assumed it was only about making them equal weight as one does with the pistons.
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Rockatansky
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Posted: 09-January-2026 at 3:54PM |
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yes the rods are weight matched at both ends, in the balance calculation the small end is reciprocating weight and the big end is rotating mass. never heard of that piston, probably because it's for a 240-6 LOL but makes sense for a stroker. depending upon the cam and valve sizes you may need to cut on the valve reliefs some?
Edited by Rockatansky - 09-January-2026 at 4:00PM |
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RacerJames
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Posted: 14-January-2026 at 11:05AM |
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Actually if you cross it in an early 2000's Clevite catalog the Perfect Circle number becomes Clevite 224-1916 which is a 302 piston. The box wouldn't have 8 pistons in it if it were for a 240. That said, I wouldn't be surprised that they are the same piston.
I plan to mock one cylinder up with a head and everything to check valve clearance with some clay, just to be sure I won't be smacking a valve. The internet guys don't mention any interference issues, but I try to trust but verify. Waiting on Summit to deliver the crank and main bearings, then I can start putting things together and measuring.
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Rockatansky
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Posted: 14-January-2026 at 12:05PM |
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240, 289 & 302 1.585" CH but they're not giving dish volume, what's the crank stroke and what rod are you using? in what block?
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RacerJames
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Posted: 15-January-2026 at 4:03AM |
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Dish volume is 12 cc, same as the pistons I measured earlier. I bought the eagle crank from Summit. Crank stroke is 3.85 and uses standard 351W bearings stock 351W rods (5.956) Math's out to 9.466 in my 9.48 69 351W block. I plan to use '69 351W heads with 60 cc (According to google) chambers. This combo will make an engine which displaces 398.75 CI and has 10.65:1 compression. Essentially the same compression as an original '69 351W 4V which came with forged flat top pistons. I also have a set of: C6AE heads (ported) with 54.5 cc chambers (according to google) This combo will make an engine which displaces 398.75 CI and has 11.3:1 compression. D5OE heads with 58 cc chambers (Measured) This combo will make an engine which displaces 398.75 CI and has 10.88:1 compression. E6SE heads with 69 cc chambers (according to google) This combo will make an engine which displaces 398.75 CI and has 9.72:1 compression. E7TE heads (ported) with 61 cc chambers. (according to google) This combo will make an engine which displaces 398.75 CI and has 10.54:1 compression. Once I have the block cleaned, bored and new cam bearings installed so I can mock it up I'll measure and publish my findings. I think this build merits it's own thread so I'll start one with a proper title.
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RacerJames
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Posted: 21-January-2026 at 11:32AM |
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I measured the D5OE heads I have and in order to remember my results I wrote them on the part. Here's a pic:
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