jdraper, yes, I know the cylinders are cast into the block,
but if you were to try a re-sleeve, the block would have
to be machined to accept seals top and bottom, also
there would be no more aluminum around the cylinders,
it would be this huge gaping hole in the middle of the
block until the cylinders are pressed into place.

Cummins Diesel Engines are built like this, and at Ohh
about 25:1 Compression ratio, I think the design is sound,
that and the fact that these engines have been around for
a long time shows the durability of this design.

I'm not saying you are wrong in your statement, just that I
think outside the box, and can see some other solutions to
an otherwise not doable situation.

A German maker who make ultralight engines uses a metal
they call Nicasil or something like that, it is aluminum, with a
high content of nickel and silica to give it a hard surface, but
it still has the thermal propertys of aluminum both in heat
transfer and expansion and contraction, steel and aluminum
have different expansion rates, which is one more good
reason to let your engine warm up before driving it hard, that and
a good reason to have cylinders that are not fixed into the block.

Besides anytime someone says "you can't do that" It makes me
want to try it ever more.  LOL

FYI, Nicasil is basically the same thing the aluminum Porsche blocks use.

Wildgoody, I'm a custom product development engineer, so thinking outside the box is the norm for what I do.  I didn't say it was impossible anywhere in my statement, I just said the chances of doing it successfully are practically nil.  Looking at my 1.3 with the head off (as it is right now  :-/ ) there isn't enough material there to successfully machine out the liners and install larger new ones.

The Cummins engines you are talking about are designed to be made/rebuilt in that manner, the Zuk engines are not.  There's absolutely nothing wrong with designing an engine like that, but to take an engine that's not designed that way and try to convert it probably won't work.  The Cummins motors have a much larger thermal mass around the cylinder liner and more material to press into.  I would hazard a guess that you could successfully machine out the liners in the Zuk motor, but you would crack the aluminum trying to press a new sleeve in because there just isn't enough aluminum there to hold up to the forces necessary.

Hot and cold press fit.

OK, now that could be a problem, scrawny blocks
without enough meat to work with   , I hope
your happy, dashing my dreams of a 90mm bore
piston, *sniff* now I'm depressed,     Wait, I know
................  



Darrin

yep that means my 2 liter bottle of diet coke win's again

OK, now that could be a problem, scrawny blocks
without enough meat to work with   , I hope
your happy, dashing my dreams of a 90mm bore
piston, *sniff* now I'm depressed,     Wait, I know
................  



Darrin

Yeah, when I popped the head off the Sami, my first thought was "where's the block??"  There's not much metal there.  The coolant passages are large and very close to the cylinder liners.  I'm guessing there's not more than 1/8" wall, if that between the cylinder liner and the coolant passages.  The damn thing's so lightweight you don't even need a hoist to pull the motor.  Hook a chain on it, stand on the fenders and just lift!  I think the Briggs in my tractor has more meat!

Heh, I'll second that, even the 1.6 is light, makes a guy feel pretty manly indeed being able to lift a long block by himself.