The reason why i chose the crank, rod, piston pin height, and cam size was becasue I knew it could be done. As a matter of fact Sonny Leonard did a bunch of these same size motors years back with the same merlin block I have in iron and aluminum block version. Now I can say that at that time the 5500 series GRP rods were not available, however, the crank size, aluminum rods and 55mm cams were available at that time. Its been done so its not a new combo by anymeans. The idea of changing blocks is not going to happen, To expensive since all the machine work is done with this one I have. The idea of changing rods is also not going to happen. Any aluminum rod set is going to cost over $1100.00 and last I knew there are not many people racing that can piss away that kind of money. Not bashing anyone so don't take it the wrong way
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After spending a few hours looking and thinking about this in front of my mill, I started by running some test passes on some aluminum plate I had and wanted to see if I could duplicate the finish of the rods. Yup, I could. So I have found a nice way to secure and locate the rods with the ways you guys have suggested and I am confident that I can take care of this issue myself. I just have to pick up some dyken blue layout paint and set the rods in place and make some marks. The only thing I am rethinking is the idea that Bill Jones had about the 6" cutter. I think thats a nice radius for cam relief but I have to see if I can locate a cutter like that. Wouldn't be a bad idea to own a cutter like that anyways. But today I was making my test cuts with a two flute 3/4" end mill with good results.
OK a couple other questions,
I have been setting up rotating clearances at .080 to .090 on this motor due to crank flex with this big arm. So should I have that same clearance at the cam as well? I am thinking the answer is yes.
Another question, IS the lobe closest to the rod when the cam is advanced or retarded? I can't remember but i am thinking when I go to measure I should set the cam for some lee-way.
Also shoudl I just mill the four rods that hit or do all eight to keep the weight the same and then have them balanced? I have not had the rotating assembly balanced yet so balancing the rods is an option for me. The balancing is going to be my next step after I straighten this glitch out.