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Boring 2.7 Mahle Alusil cylinders from 90mm to 92mm

Can you safely bore a 2.7 Mahle Alusil cylinders 90mm to 92mm? If so, do they have to be recoated?

Old 02-18-2020, 12:05 AM
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Yes you can, and yes, you do need to have them re plated. US Chrome offers this service. Better yet is to bore for steel sleeves, as the cylinder gets pretty thin in the spigot area. We bored, and pressed in 93mm sleeves for our 2.7 short stroke engine.
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1969 911TR lightweight, 1850 lb. 245 HP 2.7 short stroke
1973 1/2 911T S optioned sunroof coupe (in progress)
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Last edited by rgofast; 02-18-2020 at 07:30 AM..
Old 02-18-2020, 07:27 AM
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rgofast, what Brand 92mm pistons would you recommend? Also what compression?
Old 02-18-2020, 08:07 AM
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I have Cosworth. I’m at about 9.5 to 1. Get the pistons first, so who ever does the cylinders can fit them properly. Different brands of pistons sometimes recommend different clearances, etc. Check with Don Weaver at Engine Builders Supply. They can do your cylinders and supply the pistons. Follow his recommendations.
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1969 911TR lightweight, 1850 lb. 245 HP 2.7 short stroke
1973 1/2 911T S optioned sunroof coupe (in progress)
1998 993 Carrera Cabriolet PSS10 lowered E88 cup wheels
1999 996 Carrera Cabriolet
Old 02-18-2020, 09:24 AM
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I just nabbed a set of 92mm from Don at Engine builder supply, they have them done by Millenium cylinders. Really nice quality.

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Old 02-18-2020, 09:33 AM
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