Howdy back Ken and All:
There are two other options to consider to solve the huge 250 deck height problem. they are;
1. Use a longer 300 Ford six rod with the Keith Black 305 pistons with a 1.26" deck height. This combo has the advantage of reducing the deck height .090" and giving a slightly better rod/stroke ratio.
Rod Length & weight;
250 =5.88" 592 grams
300 =6.21" ??? grams
Difference = .330" longer
Rod Length to Stroke ratio;
250 = 5.88" : 3.91"= 1.5:1
300 = 6.21" : 3.91"= 1.58:1
Deck the top of the block to achieve zero deck height. Use a FoMoCo composite head gasket (NOS if you can find one) with a compressed thickness of .037". I'm hoping Mike will announce the Cortico .038" gaskets for 200/250 soon.
Use with a Chevy 305 Keith Black (KB 153) piston in a standard bore of 3.736" with a 1.26" pin height. These pistons would require an overbore of .056". Plans would include milling a recess into the piston top which mirrors the combustion chambers. The goals will be to create a higher quench-to-bore ratio, lower CR, lighten the piston, reduce knock tendency, and maximize combustion efficiency.
The advantages of using the 300 rods are- longer, for a slightly improved rod-to-stroke ratio, likely tougher than 250 rods. The 300 are designed for higher load truck application and have the same rod and main journal dimensions as a 250 I think.
The only extra machining would be to rebush the small ends to accommodate the larger Chevy .9273" wrist pin. The 300 rods small end measures .9122".
2. Use longer 1986-’90 Taurus & 1986 Sable 2.5 HSC rods with the flattop HSC or OEM dished replacement pistons. This has the advantage of reducing the deck height .110" and giving a slightly better rod/stroke ratio.
Rod Length & weight;
250 =5.88" 592 grams
2.5 HSC =5.99" ??? grams
Difference = .110" taller
Rod Length to Stroke ratio;
250 = 5.88" : 3.91"= 1.5:1
2.5 HSC = 5.99" : 3.91"= 1.5319:1
Deck the top of the block to achieve zero deck height. Use the thinnest composite head gasket available to optimize the quench effect.
Use with an HSC flattop piston, with plans to mill a "D" shaped dish into the top. The goals will be to create a higher quench-to-bore ratio, lower CR, lighten the piston, reduce knock tendency, and maximize combustion efficiency. The stock replacement large dish Calif Emmissions pistons would work too. Standard overbore sizes would apply to both of these pistons.
The advantages of using the 4-cyl rods are- longer, for a slightly improved rod-to-stroke ratio, tougher than I6 gear. The four cylinders vibrate much more, rev to a much higher RPM, produce more power per cylinder, carry more load per cylinder than a six, and suffer more detonation than a I6 was ever designed for.
These combinations will have a more ideal deck clearance, likely have a lighter reciprocating weight, and be able to tolerate CR in the 9.5:1 range, at sea level, with 91 octane gas.
Plans are to use ARP rod bolts, polish the rod beams, balance the whole rotating assembly, and polish the piston tops and the chambers.
In any case, mill the head only enough to ensure it's flat. It is critical to measure all volumes to verify CR. Reshaping the combustion chambers to reduce CR, unshroud the intake valves and match chamber volumes may be necessary.
A couple more options to consider.
Adios, David