World Products Man O' War Windsor Style Crate Engine
Hiding A 460-Cube Package In A 351W Wrapper With World Products' Man O' War Windsor-Style Crate Engine
From the October, 2010 issue of Modified Mustangs & Fords
By Barry Kluczyk
Photography by Barry Kluczyk
Tech | Engine Build
A displacement of 460 cubic inches never fails to conjure mental images of battleship-heavy lumps of iron torn out of worn-out '70s trucks or Lincolns, and stuffed into early Mustangs. Those classic engine swaps typically strained the front suspension and left little room under the hood for routine maintenance, let alone swapping headers easily.
But this is the 21st century and we've got World Products' innovative Man O' War Windsor-style cylinder block architecture on which to build big-inch-make that huge-inch-small-block engines. With guidance and input from a prominent NASCAR Ford entity, World Products revamped the basic 302/351 block design to bulk it up in key areas, such as the front and rear bulkheads-each is about an inch thicker than the stock Ford 302 block. Iron was added, too, to the cylinder banks to add strength and provide water passage room for large-displacement combinations.
World Products' Man O' War...
World Products' Man O' War 351 Windsor-style block is the foundation for the Limited Edition 460 crate engine. It is thicker and sturdier in key areas than Ford's production blocks, which makes the block stronger and capable of supporting such a large-displacement combination. In this case, it's a 9.5-inch-deck/351-style block with 4.155-inch bores.
The result is a block that weighs about 60 pounds more than a standard Ford 302 block, but is considerably stronger throughout. The thicker iron is complemented with standard splayed, four-bolt billet steel main caps, which should all but eliminate the tendency for catastrophic cracking that is common with the production blocks at high horsepower levels. It is a problem racers have tried to prevent through the use of main cap stud girdles and other methods, but too much boost or nitrous can split the 302 through the lifter valley like a California seismic fault line.
Apart from some obvious bulges around the cylinders, which support the block's extra "meat" and generous water jackets, the Man O' War blocks looks just like a Blue Oval casting. In fact, it was designed to accept all of the components and accessories that were ever bolted to a 302 or 351 at the factory. World Products offers the Man O' War in four deck heights, including 8.200 inches, 8.700 inches, 9.200 inches, and 9.500 inches. The 8.200- and 8.700-inch decks are 302-style blocks, while the two taller decks are 351W-style blocks. The minimum deck thickness is 0.600-inch.
A close-up of one of the block's...
A close-up of one of the block's "China" walls shows a clear advantage in thickness and strength over the OEM block. The front wall, seen here, is about 1 inch thicker, but all of the added material is carried inside the casting, so all the standard 351 accessories and parts bolt up.
Add to all these versions either 4.000- or 4.125-bores, and the capability of a 4.250-inch-stroke crankshaft, and it means a plethora of possible combinations with displacements that simply weren't practical with a factory Ford block. World Products has designed and tested a number of different combinations that are sold as crate engines, including the 460-inch version that we're examining in this story.
It's at this point we should mention that World Products has altered the way it offers crate engines. Rather than building them all in-house, the company recently began turning over the engine-assembly duties to affiliate builders around the country. Think of it as the way Coca-Cola hits the shelves via regional bottlers-World Products provides the secret recipe and supplies the ingredients, while the builder assembles and tests the engines to the company's guidelines. More about the engine-building program is available on World's website at www.worldcastings.com.
The engine depicted in our story is rated at 600 horsepower and 575 lb-ft of torque. As you'll see on the accompanying dyno chart, it made more than that, but the advertised power rating is a target that is designed to be attainable by builders in different parts of the country, who must deal with a variety of atmospheric and altitude conditions.
It is a small-block after...
It is a small-block after all, so to make room for the far-swinging reciprocating assembly and long-stroke combination, the bottom of each cylinder is notched.
Our project engine was assembled and tested at World's Ronkonkoma, New York, headquarters.
Build details and dyno testing
World's Man O' War 460-inch crate engine starts with a 9.500-inch deck 351 block, with 4.155-inch bores and the maximum 4.250-inch-stroke crank. That crankshaft, naturally, is forged steel-an Eagle 4340 forging, to be exact. The bottom of each cylinder is notched to make room for the long-reaching H-beam connecting rods.
The reach for this 460-cube...
The reach for this 460-cube monster small-block comes from a 4.250-inch stroker crank from Eagle. It's a bulletproof 4340-forged steel piece and is internally balanced.
The Man O' War block has splayed...
The Man O' War block has splayed four-bolt main caps. The main caps are billet steel and the fasteners for the inner bolts consist of studs and nuts. This, along with the block's thicker and stronger casting, makes the conventional stud girdle unnecessary.
The long-stroke crankshaft...
The long-stroke crankshaft is complemented by 6.300-inch long Eagle 4340-forged H-beam rods.
A set of World Products forged...
A set of World Products forged aluminum pistons (with coated skirts) rounds out the rotating assembly and delivers an 11.1:1 compression ratio.
The camshaft is a hydraulic roller from Comp Cams, with big 0.669-inch/0.676-inch lift specs, along with 254/260-degrees duration and a 110-degree lobe separation angle.
Atop the block is a pair of World's own 18-degree aluminum cylinder heads, which boast large, 225cc intake runners that feed fast-burn-style 72cc combustion chambers (an upgrade to CNC-ported versions of the heads brings enormous 242cc intake runners, which is good for about another 50 horsepower). The tunnel-like intake paths are considerably larger than comparable Ford heads, which have 224cc runners. The valves are matched to the heads' tremendous flow, measuring 2.055 inches on the intake side and 1.600 inches on the exhaust. Make no mistake, these are huge-flowing heads, but very necessary for an engine with such a large displacement.
The next item in the block...
The next item in the block during the assembly is the camshaft. It is a hydraulic roller from Comp Cams, with specs that include 0.669/0.676-inch lift, 254/260-degrees duration, and a 110-degree lobe separation angle.
Not surprisingly, stiff, dual 125-pound per inch valvesprings (1.437-inch-diameter) complement the valvetrain, along with cus-tom aluminum roller-tip rocker arms with a 1.72:1 ratio. They're mounted on screw-in studs. Also, the Man O' War block can accept two additional head bolts per cylinder, which provide an extra measure of sealing for forced induction and nitrous applications-power adders were not in the plans for our project engine. To feed the 460's big passages, a 1,050-cfm AED-built Dominator carburetor is mounted to World Products' single-plane, high-rise intake manifold.
During our test, World's 460-inch Windsor-style engine's 632hp peak was achieved at 6,000 rpm. World says the engine's upper limit is about 6,500 rpm. Peak torque registered 618 lb-ft on our test, and was reached at 4,800 rpm. But there's definitely more to the numbers than the peak figures: The "little" 460 made more than 560 lb-ft at only 3,500 rpm and crossed the 600 lb-ft threshold by 4,400 rpm.
On the horsepower side, it hit 400 horses by 3,700 rpm and curved smoothly upward toward its peak, crossing 500 horsepower by 4,400 rpm and 600 horsepower by 5,200 rpm. Clearly, the deeper this big-volume engine breathes, the stronger it gets, but we were surprised by how well the engine idled and performed at low rpm.
With the crankshaft and camshaft...
With the crankshaft and camshaft installed, a double-row timing chain is installed and the camshaft is degreed. It's easier to make adjustments when only the crank and cam are in the block
With its big cam and high-rise single-plane intake, we frankly expected a bit of stumbling down low. We saw none. Of course, the dyno is a different environment than the street, but not enough to drastically alter the attributes we experienced during testing. There's a lope to the idle no doubt about it, but this engine shouldn't be a problem for cars with power brakes, and more.
For us, the prospect of popping the hood at cruise night and answering "460," when someone asks, "watcha' running?" and stares at an obvious small-block package will be worth it. Of course, there's something to be said for keeping mum about the displacement-especially for those forays to the track-and let the bystanders scratch their heads after viewing the Windsor package under the hood.
With this 460-inch combo, there's no reason to make compromises with the front-end weight penalty or tightly packed engine compartment that comes with a 385-family 460. And, frankly, for the World Products engine's approximate $15,000 price tag, you'd be hard-pressed to build a vintage 460 to make similar power for less, and it simply wouldn't have the lower-mass advantage. Indeed, for a pro-touring-style '68 Mustang fastback or a '71 street/strip car, this 460-cube package in a 351-inch wrapper has much to offer.
A Moroso deep, dual-sump oil...
A Moroso deep, dual-sump oil pan is standard and is designed for the typical Ford crossmember found in classic Mustangs and other vintage Fords. Beneath the pan is a Melling high-volume oil pump, pick-up, and more.
The Limited Edition 460 comes...
The Limited Edition 460 comes with aluminum versions of World Products' 18-degree cylinder heads. They're available in a variety of configurations, but for our mega-inch Windsor, they feature cavernous 225cc intake runners that flow about 300 cfm at 0.800-inch lift at 28 inches of water.
The Manley Severe Duty valves...
The Manley Severe Duty valves in the 18-degree heads are 2.080 inches in diameter on the intake side, and 1.600 inches across on the exhaust side. They're the big doors to 72cc fast-burn-style combustion chambers that promote a quick, more complete burn of the mixture.
Take a closer look at the...
Take a closer look at the installed cylinder heads and you'll see dual, 1.437-inch diameter springs with dampers. They are rated at 125 pounds per inch and can handle up to 0.700-inch lift. Locks and retainers are from Manley, while the springs and valve seals are World Products' own parts.
Custom 1.72:1-ratio aluminum...
Custom 1.72:1-ratio aluminum roller rocker arms from Scorpion are used in the 460. They mount to screw-in studs and complement custom 8.500-inch-long, 5/16-inch pushrods.
Another World Products-manufactured...
Another World Products-manufactured component of the assembly is the high-rise, single-plane intake manifold. It has a "spider"-type design, with individual intake runners that are excellent at increasing the mixture velocity as it is channeled into the heads.
|Man O' War 460 Limited Edition|
|Engine type||OHV V-8; iron block with aluminum heads|
|Displacement||460 cubic inches|
|Cylinder block||High-density cast-iron|
|Main bearing caps||Four-bolt splayed; billet steel|
|Deck height||9.500 inches|
|Cylinder bore||4.155 inches|
|Crankshaft||4340 forged steel|
|Connecting rods||4340 forged steel H-beam|
|Pistons||Forged aluminum with coated skirts|
|Piston connecting pins||Full floating|
|Camshaft||Hydraulic roller; 0.669/0.676-inch lift; 254/260-degree duration; 110 LSA|
|Timing system||Double-row chain|
|Cylinder heads||World Products 18-degree; 225cc intake runners|
|Valves||2.055-inch intake; 1.600-inch exhaust (stainless steel)|
|Valvesprings||Dual 125-pound per inch|
|Rocker arms||Aluminum roller; 1.72 ratio|
|Pushrods||4340 forged steel, one-piece (used with guides)|
|Intake manifold||Single-plane high-rise|
|Carburetor||1,050 Dominator (4500 series)|
|Miscellaneous||Spark plugs, plug wires, oil pan, polished valve covers, SFI balancer included|
|(engine tuned with 30 degrees total timing)|
|Peak numbers in bold. |The Aluminum Option
This isn't a bare, unpainted...
This isn't a bare, unpainted iron block. It's an aluminum Man O' War Windsor-style cylinder block casting. In the same 9.5-inch deck size as the block in our main story, this lightweight version weighs a scant 90 pounds.
Aftermarket aluminum engine blocks have traditionally been left to the domain of professional racers, thanks to prices far greater than their weight savings. World Products is changing the status quo, however, with lower-cost aluminum castings, including an alloy version of the Man O' War block. That is due to an innovative machining process that World Products says dramatically shrinks the time and effort involved in finishing a rough casting.
A unique feature of the aluminum...
A unique feature of the aluminum block is a series of cross-valley ribs that enhance the strength of the block and carry additional oiling galleries.
The aluminum Man O' War saves about 100 pounds when compared to the weight (including main caps) of the iron version and adds about $2,000 to the price of a crate engine. That is only about a 15-percent premium on the cost of the crate engine described in our main story. A 15-percent premium may be the cost, but to paraphrase a popular advertising campaign, the exotic allure and "wow" factor of an aluminum Windsor block is priceless.
Fuel and air meet in a 1,050-cfm...
Fuel and air meet in a 1,050-cfm "Dominator" carburetor. World Products specs an AED-built carb, which is modified by the company for greater reliability and easier tuning. That's a big carburetor for a small-block Ford, but then again, at 460 cubic inches, it's a huge small-block that's capable of moving a lot of air.
A high-energy distributor,...
A high-energy distributor, such as an MSD or Mallory, is part of the crate engine package, along with all of the plugs and plug wires. The distributor is equipped with a plug-in for an ignition box.
All buttoned up and ready...
All buttoned up and ready to rock. The Man O' War 460 represents the pinnacle of crate engine offerings based on World Products' Windsor-style architecture. It's rated at 600 horsepower and 575 lb-ft of torque, but made 632 hp and 618 lb-ft during our test. Not bad for a small-block that takes up no more space under the hood than a standard 351.