Lifter Preload, symptom diagnosis
Cam specs: 224/230@114 .581/.588, XE-R lobes
Initially I was running comp magnum 7.425" pushrods. Car ran great, valvetrain was quiet, no problems. Began a few idle tuning sessions, logging airflow and letting the engine heat up to 220 degrees or so. On roughly the third session, one of the lifters for the number one cylinder (i suspect) began to tick. It will stay quiet regardless of temperature until I blip the throttle, then it begins to clatter away. The tick will not go away regardless of rpm or temp when it begins. I used a large screwdriver to pinpoint the location of the tick. I can also hear it out the exhaust, which makes me suspect it is the exhaust valve lifter. This is not a faint tick, it is very loud and noticable.
I began to question my lifter preload, so I used a pushrod checker to find the length at which I was at 0 lash and 22 lb/ft, measuring at the base of each lobe. I double checked each measurement by reinstalling the 7.425 pushrods and using the turn method. Both measurments matched up. Cylinders 1, 3 and 5 were measured. Each valve on these cylinders was close in length when finding zero lash - roughly 7.3 inches. This meant that I had .125" of preload!

Comp recommends 7.4" PR for this cam, which still seems to be too much. From everything I've read, the LS7 lifters like to be around .080 but others have recommended .050 as the ideal measurement. This would mean I would need between 7.35-7.38" pushrods. This seems a bit contradictory to what should be happening. Since the base circle of the cam is smaller, I would have assumed that I would need a longer pushrod. Just for the hell of it, I through in the stockers at 7.38". I fired it up and let it run for about 30 seconds, plenty of time for the lifters to pump up. With the stockers, it was clattering like crazy from what I'm assuming was way too little preload.
What is happening here? What am I missing?

Thanks in advance for the help. Sorry for the long read.
edit: "Roughly 7.3 inches" doesn't get it done, need a measurement out to 0.00x" to be of any use.
Assuming LS7 lifters, I'd go with 7.400" pushrods.
Not sure why your stock pushrods were noisy as they should be just barely within preload range.
Did you tighten your rockers using the GM procedure so the lifters were on base circle, or run 'em down all at once and bottom out several of your lifters in the process?
When started, the engine was hunting for an idle and eventually died. It didnt pick up and idle like it should/did before the new pushrods. I appreciate the insight.
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That said, I am always surprised when people are surprised their ls7 lifters tick. We are talking about a high tolerance part consisting of several moving pieces and a good amount of steel that costs about the same as a pushrod.


