Boring Alusils from 95mm to 98mm?

WydRyd · 09-13-2004, 07:03 PM

Hi,

I have a used set of good Alusil Cylinders and I was just wondering if anyone here has ever bored out Alusil cylinders?

Once bored, can they be re-plated in Nikasil or Electrosil?

Just contemplating the idea for a future upgrade path, using JE 7.5:1 Pistons.

KobaltBlau · 09-13-2004, 08:51 PM

Yes you can bore them to 98mm and replate them in nikasil. If they are from a Carrera 3.2 no problem. with 3.0 cylinders you have to worry about the sealing ring groove. EBS racing does this here in the US. US Chrome can also do the plating but I'm not sure if they do the machine work.

geof33 · 09-13-2004, 09:48 PM

3.2's... yes... 3.0's... no... Eric is correct...

WydRyd · 09-14-2004, 09:20 PM

Cool, thanks guys!

I guess I will hold onto my used set then, for a rainy day

jimz61 · 09-20-2004, 11:25 AM

I'm also under the impression that 3.3 is a no. Can't go 97 to 98mm.

Alan.UK · 09-21-2004, 09:54 AM

What about the 95mm cyclinders from an early turbo, can they be used ?

Alan.UK

ChrisBennet · ChrisBennet's Garage

Quote:

Originally posted by Alan.UK
What about the 95mm cyclinders from an early turbo, can they be used ?

Alan.UK

Not if they have the sealing rings. I can't remember if those do.
-Chris

red-beard · red-beard's Garage

See the thread on Alusil. They do not need to be coated. The Silicon goes all the way through the part. It will need to be honed using the special paste.

WydRyd · 02-12-2007, 07:52 PM

Just thought I'd revive this thread.

So, if I bore out my original 95mm 3.2 Carrera KS Alusils, I don't need to re-coat them in Nikasil?

Who offers the best boring / honing service and how much does it typically cost for a set of 6?

Also, my Alusils are magnetic inside. I though Alusils aren't megnetic and only Nikasils are?!?

Can someone confirm please?

Lukesportsman · 02-13-2007, 06:51 PM

Merv,

Certainly the KS may have consistant alloy all the way through. BUT, If you don't wish to buy KS pistons in the larger diameter.....and you don't for the boost your running then YES coat for JE's.

I believe your thought pattern on magetism is correct.....hmmmm. Dumb question, how did you determine they were Alusils to begin with? Are they shiny on the outside, kind of like cheap Al paint appearance or do they look similar to your Mahl from the outside?

89turbocabmike · 02-13-2007, 07:59 PM

merv, I've got two sets of 3.2 cylinders here, one alusil and the other nikasil. Only the nikasil are slightly magnetic. The nikasil have a traditional cylinder look/color with cross-hatching, the alusil have a uniform frosted silver look without any honeing marks. I'll get some pics posted up soon.

WydRyd · 02-24-2007, 04:27 PM

Quote:

Originally posted by Lukesportsman
Dumb question, how did you determine they were Alusils to begin with? Are they shiny on the outside, kind of like cheap Al paint appearance or do they look similar to your Mahl from the outside?

Well, they are definitely KS cylinders, which I was led to believe were ALL Alusils. The outside is not shiney... they look like MAHLEs. Here's some pics:

Eagledriver · 02-25-2007, 07:32 AM

I would say those are alusil based only on the first picture. Do you see how the light reflects off the fins in the first picture? The alusil cylinders look almost glassy on the outside when they are cleaned. Put them in the dishwasher (when wife is not home) and you'll see them look shiny on the outside. They can be plated to nikasil if you desire.

-Andy

89turbocabmike · 02-25-2007, 09:48 AM

Yup, I'd agree those are alusil, they have that uniform frosted silver look. Also take a small magnet(the stronger the better) and place it in the bore. The nikasil's will have an obvious attraction dependant on the strength of the magnet, the alusil's none.

Lukesportsman · 02-25-2007, 11:37 AM

It doesn't really matter what they were originally as long as they ARE 3.2's which they are since they're from your 3.2. You might as well bore out KS cylinders since they have virtually no resale value. Though when I last checked in USA, they were getting about $1200 for a bore and plate. This puts them pretty close to other options out there.

A curious note: Would KS metallurgy be any better with JE's than the known problems of Mahles? Maybe Charles N. will chime in on the this aspect when the work week begins.

WydRyd · 02-25-2007, 10:22 PM

Quote:

Originally posted by 89turbocabmike
Yup, I'd agree those are alusil, they have that uniform frosted silver look. Also take a small magnet(the stronger the better) and place it in the bore. The nikasil's will have an obvious attraction dependant on the strength of the magnet, the alusil's none.

I've done this test and there is a DEFINITE attraction to the bore. The magnet sticks to the bore! I'm not sure what this means, but I assume it has probably been plated with Nikasil sometime in it's life, since everyone tells me that Alusils do not attract magnets!

Steve Weiner quoted me in the $800 region to have them bored to 98mm and replated in Nikasil, which I think is a pretty darn good price (& I trust Steve would do them properly). Add a set of turbo spec JE's for $800 and you're good to go. I wouldn't run extreme boost with such a configuration, but for 1.0bar @ 7.5:1 C/R, they'd live fine.

Hmmm, food for thought