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Alusil Cylinder, how should it look?

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Old 03-07-2015, 10:21 AM
  #31  
Voith
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I think it was done to keep the air turbolence down so that flow trough new ports is smoother.

In turbo application it makes more sense to let those spaces to cool with oil than to leave them to heat up more than water cooled part of cyl.
Old 03-07-2015, 05:43 PM
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For the record, part of KS manual with AluSil info.


Old 03-07-2015, 09:21 PM
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Blade 7 . There is a reason as to why I built 944 spec engines in San Diego and why I now work in the Vehicle Engineering Test Group at Tesla Motors

Last edited by kev951; 03-08-2015 at 04:33 AM.
Old 03-08-2015, 04:45 AM
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I think the bores looked good in the dull photos, the shiny ones had me worried a bit...


Old 03-08-2015, 09:09 AM
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Originally Posted by kev951
Blade 7 . There is a reason as to why I built 944 spec engines in San Diego and why I now work in the Vehicle Engineering Test Group at Tesla Motors
OK, but with the greatest respect to Voith I don't think he's got your experience.
Old 03-08-2015, 09:06 PM
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Thats why I am here. To learn.
Old 03-08-2015, 09:25 PM
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Originally Posted by Voith
Thats why I am here. To learn.
No offence intended buy a telescopic gauge and have a practice measuring a cylinder.
Old 03-09-2015, 02:25 AM
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Originally Posted by kev951
Blade 7 . There is a reason as to why I built 944 spec engines in San Diego and why I now work in the Vehicle Engineering Test Group at Tesla Motors
Can't imagine what working at Tesla has to do with measuring piston bore diameters!

Seriously, though, any tips to share on using snap gauges to measure piston clearance? I couldn't do it. Bought a .0001" dial bore gauge on ebay (Starrett 84) which was much easier to use.
Old 03-09-2015, 09:11 AM
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Originally Posted by Dare

Seriously, though, any tips to share on using snap gauges to measure piston clearance? I couldn't do it. Bought a .0001" dial bore gauge on ebay (Starrett 84) which was much easier to use.
I find them tricky to use, making sure you are at the largest dia of the bore and locking it off it seems easy to read under. Trial setting the gauge in a mic or vernier until it fits the bore seems easier.
Old 03-09-2015, 09:26 AM
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Smaller bores are easy, 104.5 not so much.
Old 03-09-2015, 02:48 PM
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dail bore gages can scratch the cylinders finish..
Old 03-13-2015, 04:35 AM
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Better safe than sorrow. I will do the lapping part myself, manual says it it self limiting procedure so Id rather see silica is more exposed than less.



Last edited by Voith; 03-13-2015 at 06:11 AM.
Old 03-13-2015, 11:29 AM
  #43  
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Have you seen these:

Reconditioning of Aluminum Engine Blocks

Reconditioning High-Silicon Aluminum Alloy Engine Blocks with Sunnen AN-Series Hones

Honing Options for Hypereutectic Aluminum Cylinder Bores
Old 03-13-2015, 12:00 PM
  #44  
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Havent seen the first one, Ive read other two trough and much of the KS AluSil manual.

Second link you posted contains this:

The final exposure step requires a new specially developed, elastomer-bond abrasive (XM27), using light honing force. For the exposure step, we recommend tooling with the greatest abrasive surface contact area. This step is based on time, typically 1-1 ½ minutes for 19 µin. (0.5 µm) exposure height. Longer cycle times are not harmful, because the process is somewhat self limiting. It is absolutely critical that honing force or pressure be kept as low as possibly, while still maintaining tool stability. Surfaces shown in the accompanying illustrations were honed with less than 5 lb/in2 pressure.
I will gently rub AN-30 in it for another minute per bore.
Old 03-13-2015, 02:42 PM
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Originally Posted by Voith
Better safe than sorrow. I will do the lapping part myself, manual says it it self limiting procedure so Id rather see silica is more exposed than less.


How do you attach the felt pads to that ?


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