Production engine blocks can only be expected to hold up to just so much power. Even old school iron blocks will let go at some point and the easy availability of twin-turbo setups these days just brings that day of disaster ever closer. When it comes to looking for a GM big block, one of the classic starting points is the 409ci engine. Popular? How many other engines do you know of that the Beach Boys wrote a song for?

World Products’ aluminum 409 engine block is an intriguing alternative to searching junkyards for ghosts of decades past. The aluminum construction takes 140 pounds off the front end of your ride, while delivering a stronger block that can use many original 409-style components. While World Products took pains to ensure that the appearance of the block is consistent with the original, changes inside are what help deliver the goods.

Cylinder bores were increased to 4.5″ diameter, which require do custom pistons with 409-style domes. The crankshaft has been moved out by a quarter-inch, which provides a variety of stroke length options, up to 4.75 inches and a maximum displacement of 632ci. Four-bolt main bearing journals replace the two-bolt original design, enabling support at significantly higher power outputs. In all, the list of innovations in the new block hits the two dozen mark and provides a much greater degree of flexibility in component selection than was previously available.

Developed in conjunction with W big block guru, Lamar Walden, the best of old and new is present in the World Products’ block. “Common sense prevailed in the selection of parts; they are now all premium components, readily available, and economic to all pockets,” Walden pointed out.

Additional information on the World Products’ 409 Block is available from the company’s web site.