Superfly- Destroyer of Hideous Camaros is near and dear to our hearts. Our once-editor (now editorial director) Jim Campisano has used this project '97 SVT Cobra in nearly all facets of motorsports. Its high-revving N/A Four-Valve has left many shaking their heads in disbelief with its 11-second timeslips and on-track abilitiesùall in street trim.
Sadly, the heart of Campy's Rio Red Snake has grown tired. Countless trips down the dragstrip shifting above 7,500 rpm and sustained high-rpm blasts around some of the most famed road courses in America have taken its toll. To be frank, the Cobra is whipped.
Last month we gave you a little history on Superfly-DOHCùthis month, we're going to talk about the new engine. We've teamed up with Ford Racing Performance Parts (FRPP), Livernois Motorsports, and many other aftermarket giants to build a 4.6L-based Four-Valve that will bring back Superfly's lost power and push the Four-Valve performance limitsùthe way Superfly did in the late '90s.
The base of our FRPP/Livernois...
The base of our FRPP/Livernois Four-Valve build is a Boss 302 block. The iron modular block is 36-pounds heavier than the aluminum version, but you instantly gain 24 ci over the stock-bore/stock-stroke version.
The foundation of the engine is an FRPP (modular) Boss 5.0 block. The big-bore block gives you 94mm (3.70-inch) bores, which are 3.8mm larger per cylinder than the stock 90.2mm (3.552-inches) bores. Another benefit is its strength. FRPP added 17mm-thick main webbing and four-bolt mains with nodular-iron main caps. The Boss block weighs in at 165 pounds, making it 36-pounds heavier than it's aluminum cousin, but the added displacement and increased strength make the small amount of added weight a non-issue.
Livernois filled the Boss block with its own rotating assembly. The crank is a Livernois 4340 forged-steel piece with a 3.750-inch stroke. It uses Livernois/Manley forged H-beam rods with ARP 2000 rod bolts to connect the crank to the custom Livernois/Diamond pistons. The pistons have coated skirts and crowns, as well as gas ports for better ring seal. The combination of the 3.700-inch bore and 3.750-inch stroke gave us a displacement of 323 ci (5.3 liters).
The short-block was topped with Livernois Stage 2 CNC-ported cylinder heads. The heads are CNC-ported on a five-axis CNC machine, and fitted with custom-ground factory-size intake and exhaust valves (36mm/1.42-inch intake, 29mm/1.14-inch exhaust). Livernois also does a four-angle valve job to finish off the heads. When all is said and done, the heads flow 310 cfm on the intake side and 255 cfm on the exhaust side at 0.500-inch lift. The heads are mated to the Boss block using ARP head studs and Cometic gaskets.
The valves are actuated by custom Livernois camshafts, which are cut by Comp Cams. The shafts measure 0.475-inch lift on both the intake and exhaust side, with a split duration of 238/238 at 0.050-inch lift and a 113.5 LSA. The camshafts use stock followers and lifters to set the valves into motion, and Livernois single-coil valvesprings return the valves to the seated position. The long-block was then topped with an '03 Mach 1 intake manifold.
When we have the engine on the dyno, we'll test the stock intake against a ported version with a variety of intake spacers. Come back next month as we strap our Livernois-built Four-Valve to the engine dyno and hopefully see some big power!

1a Livernois Motorsports...

1a Livernois Motorsports supplied one of its Four-Valve stroker kits...

1b ...The kit includes a...

1b ...The kit includes a 4340 forged steel crank shaft, forged H-beam rods, and forged aluminum pistons.

2 The block comes bare and...

2 The block comes bare and needs to be finish-machined prior to assembly. Livernois finish-honed and milled the deck surface, ensuring the deck was smooth and flat.

3 After installing the ARP...

3 After installing the ARP main studs, Bruce Martin pre-lubed the bearing with assembly lube.

4 Martin then lowered the...

4 Martin then lowered the stroker crankshaft onto the engine.

5 The Boss block comes with...

5 The Boss block comes with nodular-iron four-bolt (two top/two side) main caps. With the bearing installed in the caps and coated with lube, they are slid onto the main studs.

6 Once the main caps were...

6 Once the main caps were torqued down, Martin checked the crankshaft endplay before moving on.

7 The side bolts of the...

7 The side bolts of the main caps were then torqued to spec.

8 Livernois’ rotating assembly...

8 Livernois’ rotating assembly uses Dia- mond pistons. The forged aluminum pistons features coated skirts and crowns to reduce friction, as well as gas ports for better ring seal.

9 The wristpin bores are...

9 The wristpin bores are measured and machined to ensure they are the proper size. This allows free movement of the piston as it travels in the bore.

10 Next, the Livernois/Manley...

10 Next, the Livernois/Manley H-beam connecting rods are attached to the pistons.

11 Each piston-and-rod assembly...

11 Each piston-and-rod assembly is complete with the installation of the ring pack.

21 With the short-block and...

21 With the short-block and cylinder heads complete, its time to introduce them to each other.

22 Before sliding the ported...

22 Before sliding the ported cylinder heads onto the short-block, Martin installed a set of Cometic head gaskets designed for the larger 94mm bores of the Boss block.

23 After the heads are bolted...

23 After the heads are bolted down, the timing chains are installed next. FRPP supplied us with a 4.6L 4V Camshaft Drive Kit, which includes all of the cam gears, chains, guides, and tensioners.

12 The bearing surfaces and...

12 The bearing surfaces and wristpins are generously coated with assembly lube prior to installation.

13 Martin then installs the...

13 Martin then installs the pistons and rods into the freshly machined Boss block.

14 The rods and rod caps...

14 The rods and rod caps are held together with ARP rod bolts.

24 Next, a stock Mach 1 intake...

24 Next, a stock Mach 1 intake is lowered onto the long-block. Martin then bolts on the timing cover, which we got from MPS Auto Salvage.

25 With the timing cover...

25 With the timing cover in place, Martin installed the ATI Super Damper to keep the crank balanced and running smooth.

26 Martin finished the build...

26 Martin finished the build off with a Moroso oil pan. The pan features internal baffling, which will keep the pick-up submerged whether we are launching hard at the dragstrip or cornering at Sebring. Check back next month for our engine dyno test and ported intake test.

15 After finishing the assembly...

15 After finishing the assembly of the short-block, the block was prepped for the cylinder heads. ARP head studs were used to secure the ported cylinder heads.

16 After disassembling the...

16 After disassembling the ’03-’04 Cobra/Mach 1 cylinder heads, they are bolted to the CNC machine. Livernois uses a five-axis CNC to port its cylinder heads.

17 The finished product is...

17 The finished product is a smooth, machined surface that flows a significantly larger amount of air than the unported castings. Stock, these heads flow 267 cfm at 0.500-inch lift on the intake side, with 182 cfm at 0.500-inch lift on the exhaust side. Livernois’ ported versions flow 310 cfm on the intake side, and 255 cfm on the exhaust side, both at 0.500-inch lift.

18 Next came the valve job....

18 Next came the valve job. Livernois treated the heads to a four-angle valve job before installing the stock-size valves and Livernois single-coil valvesprings.

19 With the valve job complete,...

19 With the valve job complete, it was time to install the rest of the valvetrain. The camshafts measure 0.475-inch lift on both the intake and exhaust side, and 238/238 duration at 0.050; the cams have a 113.5 LSA.

20 The cam bearing and valve...

20 The cam bearing and valve tips are coated with assembly lube in preparation for the cams, followers, and lifters.