Replacing Cylinder Barrels/Jugs with existing Pistons and Rings.

My existing cylinder barrels are damaged externally, the two bolts at the front of the cam chain tunnel area. I have a spare set. Can I fit the existing pistons into the spare set without rehoning the spare cylinders? I know about checking end gaps of piston rings in the bores and checking the bores at the top, half way down and near the tapers at the bottom of the liners. Any advice appreciated, cheers.

 

Well you can, provided they are in good condition and within spec, and I would recomend a light hone to help everything bed in

 

Cheers minimally what hone should l get thanks?

 

Either the ball on the wire or three stones one would do - you're not wanting to remove any metal, just take the shine off.

 

Great l decided it was better to replace them than weld the original ones. Need tig gear to weld it.

 

If it's accessable I would take it somewhere to weld it - is it doable without stripping the engine? If you do the prep - cleaning etc, a decent welder should be happy to take it on.

 

I will need to take the barrels off to take to an engineer, I heard there is a welder in Shotts who does that type of repair I will contact him.

 

Ive seen Millyard heat up cylinders on his BBQ and drop/knock the liners out. If you'r bravee you could try that i.e. swap them over. BTW to measure bores properly you need
a specific bore gauge instrumsnt I think.

 

Yes that's a good idea too. I will have to put them in the oven when she is at work . Yes l have seen the gauge for the bores.

 

That would be ideal if l can swap them. I have seen people freezing the liners to get them in as well. I will watch the Millyard video again l think.

 

Here is the mess l have to fix. Steel bar holding bolts because the cylinders are damaged at the bolt holes. Some bodge this is.



I don't want to leave it like this. PO's.

 

What a mess.

 

Nooo, this is way more complicated than just knocking them out and replacing them - they were installed to a step then the whole lot machined flat - you will end up with liners up down and everywhere in between. I'm not joking, I've actually done this on a Vmax engine, same principle exactly -(with the added hassle of setting up the v engine in the mill).
You can do it, but you should still deglaze them and have them topped at a machine shop.

 

Is that plastic metal? If the bores are good get it tigged up and machined. Costly though for everything

 

The red bar is metal. These are the other barrels. I won't try and change liners. So it's either tig up the damaged ones or fit the spare ones if they are in spec and hone. I didn't realise the liners would be up and down cheers minimuttly.

 

Is the machining involved once it is TIG welded like skimming a cylinder head? Local engineers skimmed the head on a Mondeo I had before I replaced the head gasket. It was not expensive for that.

 

No, if you tig weld up the rotten lugs it will need machining to drill and face off the newmetal, and maybe reface the jugs due to distortion. I would guess £200 all in, but it depends where you take it.

 

That's not expensive if it's around that cost cheers.

 

welding probably safer but not as much fun. I agree that seating the liner again so they are all within a couple of thou' would be tricky fo the layman and a lick over by a mill probably wise.

 

Tricky for the layman? They will only go down as far as the lip lets them, and they won't match the reliefs in the "block".

 

Replacement cylinders arriving today. Local engineers will check the bore dimensions and if within tolerance as I have been assured they are they will be honed and fitted. Should I put the rings in the bores to make sure they end clearance is within specifications? If this works it is the easiest solution at the moment. And what grit of hone is necessary to remove the glaze?

 

Cylinders look to be in excellent condition but of course need them measured to be sure. No damage whatsoever and no lip at the top of the bore where the rings stop.

 

Yes to checking ring gaps. Be careful!

 

I will motor is not stripped yet.

 

Replacement cylinders look good.