In this article, John Tice will discuss the various different methods and procedures for sizing a sleeve, as well as interference fitting, and shrink fitting. - Billy
Hello Tim: Are you getting ready for the winter weather in Germany?
Your question about your liner fit is so critical and many people are unaware of its importance. I can help since I’ve already figured out a few things although you need to check them over for yourself. We’re talking about the coefficient of linear expansion. You need a set of measuring tools including a dial bore gauge. You also need a 500-600 deg. temp stick from your local welding supply. Don’t be offended when you already know some of this, it’s also for the benefit of other readers. I’ve tried looking this up but found that I needed to do it myself as you do.
I’ve found that the coefficient for aluminum is close to .005” per 100deg. This is easy for you to remember (5*5). When you heat your cylinder to 500 deg. it will expand about .025”, or 5*5=25. The rule of thumb from most everyone is, the shrink fit for a liner your size is about -.003”. There is plenty of “About & Around” in this write up. You need to confirm everything for yourself. With +.025”-.003” you’ve got .022” clearance when heated to 500deg. This is plenty of room for you to drop in the new sleeve. Still, you must move quickly in order to keep the new liner from sticking while lowering into place. (I’ll send you a copy of my Motor Math spread sheet in a separate email)
You need to measure the bore diameter of your bare cylinder both hot & cold. Write all of this down, I can never remember all of this stuff. LOL
Heating the cylinder: Any kind of torch is fine, I use a propane torch with a Weed Burner attached. You also need to be careful not to overheat the cylinder. Carefully working the torch around the cylinder gives an even heat. I keep my heat stick handy in my other hand for keeping track of the temperature. Frequently touch or draw a spot on the cylinder, when you’re up to temperature the heat stick will “Smudge”.
Find a scrap cylinder to test your skills before you have a “fin meltdown”. I learned this trick way back when that you need to use and understand. With your “Scrap cylinder”, start heating up a fin. At around 900 deg. The aluminum will start to melt. Here’s the TRICK. Just before the aluminum fin starts to melt, the heating flame will change colors to a bright Red,Orange. You need to do this; it’ll save you the embarrassment of a melted and collapsed fin or other parts.
Tapping into alignment then putting a weight on top: I use a selection of brass rods to tap the liner into alignment with the cylinder. You have 10-20 seconds to tap things around. If the sleeve gets stuck in a crooked position, you’ll probably need to cut it out and start all over. BIG PROBLEM, been there done that.
After the sleeve is in & aligned a weight is put on top to hold things in place. If you don’t weight the new liner it will raise like you squeeze your tooth paste tube. We don’t trim the upper portion of the sleeve until the parts cool off.
Heating cylinder, waiting for the sleeve to drop out. This one caught me off guard. European cylinders are usually installed with a press fit. This Husky liner was cast in and had to cut out. Be careful when you do this kind of work, it’s complicated enough that I like to stay focused. Anybody who is good at liner installation and high quality port work can probably walk on Water.
Measuring the bare bore ID while cold. I don’t know why people always carve their names on their work. Kinda catches them with their Pants Down.
Heating a Briggs bore
Measuring while hot
Fuji cylinder with new liner top view. You can see the Smudge Marks from the heat sticks.
Surfacing the top “Decking”. A .005” lip is left at the top of the new cylinder sleeve. Doesn’t matter who does the work, chances are that the new liner will drop and blow a head gasket. Enough to catch your finger nail.
Another ID bore check
Close up. .005” lip on top of new liner. New threads in the head studs. Anybody have any questions, please Chime in. We can all learn from this.