Damaged Piston Cylinder exterior (picture)

[ozzydan11]

Hi

My motor sat for three years in the garage. I decided it was time to fire her up, but no go. I checked the compression and found a low value on one cylinder. On closer inspection i found external damage on the piston housing, as shown in the photo. My question is can i simply scrape out the damaged bits and install a new gasket. It appears that about half of the diameter has cracked away and then extends nearly half way around the cylinder. Or do i need to replace the cylinder, if so can this be easily done.

Dan

 

[pnwboat]

Re: Damaged Piston Cylinder exterior (picture)

It appears that the aluminum portion of the cylinder wall has separated/cracked away from the cast iron cylinder liner. Unfortunately, this aluminum portion of the cylinder is not replaceable. It also appears that there is corrosion through the whole water jacket that surrounds all of the cylinders. This may be why the aluminum has weakened and separated. Was this operated in salt water?

 

[ozzydan11]

Re: Damaged Piston Cylinder exterior (picture)

Yes it has been running in saltwater. Do you think it is salvageable, I was hoping to put a new gasket on it and get another season out of the motor.

 

[pnwboat]

Re: Damaged Piston Cylinder exterior (picture)

You may possibly temporarily fix the problem with some metal epoxy. Here in the U.S. we have a product called "J B Weld". You can fill in the areas where the aluminum is missing. Apply enough epoxy so that it is higher than the gasket sealing surface. Once it hardens, carefully file it down to match the original surface of the block. It just might work. Make sure you clean the area well with a fine wire brush before you apply the epoxy.

 

[ozzydan11]

Re: Damaged Piston Cylinder exterior (picture)

Thanks

I'll try and track some down

 

[O.T.Water]

Re: Damaged Piston Cylinder exterior (picture)

pwn has made a good suggestion. I just had the same issue but a much smaller area. Small wire wheel on a drill and get all the loose stuff out of there, Then rough it up with a grind wheel on a dremel. Looks like you will have to do several layers to build it back up. Rough up the surface between applications. JB hardens like a rock and as it starts to cure you can mold it with a popsicle stick. Use a flat metal edge (putty knife) as it cures to keep a good edge even and level with the ends of the cylinder liners. It must be flat where the head gasket meets it. When your done and back to running make sure you flush her out with fresh water after every use. Oh yea, better check your water pump too, after 3 years it needs to be replaced. Good Luck, O.T.

 

[Frank Acampora]

Re: Damaged Piston Cylinder exterior (picture)

Take it from me: that engine is dead!

I truly enjoy ressurecting an engine, but that block would be one I would immediately throw on the scrap pile. It is not worth investing any time or money.

You can TRY the epoxy but in all likelyhood it will not work for other than a short period. That's asking a lot from even the BEST epoxy: You have heating and cooling cycles, expansion and contraction, vibration, and combustion pressures

Since the engine has been used in salt water, building up with weld is not an option either. It just won't stick.

The aluminum that has separated from the steel liner supports not only the fiber portion of the head gasket but also a portion of the steel ring. With heating and cooling, the epoxy will separate and the new head gasket WILL blow out--it is only a matter of time.

Face it: You need a new block. Start looking now.

 

[ozzydan11]

Re: Damaged Piston Cylinder exterior (picture)

What would a replacement block set me back. I am a novice and have no idea on rebuilding engines. Should i just scrap it down and sell it for parts.

 

[Frank Acampora]

Re: Damaged Piston Cylinder exterior (picture)

Bought from a rebuilder, a 4 cylinder short block will cost about 2500 US dollars-- What would that be now? About 1200 Pounds?

However, I would almost NEVER buy one that way . It is just too cost inefficient.

What you should do is look for an engine with damage such as melted pistons from detonation and use the block after having it rebored for oversized pistons which are available new.

Alternatively look for an engine with the electronics shot and swap yours into it.

These "junker" engines generally sell cheaply. Only thing is you need to invest the time and work into them to get them running.

You did not say, but that looks like a 3.375 bore engine. That would be either a 120 (4) cylinder or 90 (3) cylinder so those would be the blocks you would look for. However all electronics are swappable in like cylinder engines so if that is what you end up doing, any 3 for 3 or 4 for 4 cylinder engine swap is do-able.

Upon second look, that appears to be a 2 cylinder engine--I am not too sure about short block costs or acceptable swaps on those engines