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December 1st, 2017, 01:34 PM   #1
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Bore measurement issues

Heya Bergers.

The short version:
I have no way to measure my liner in order to spec a replacement piston.

The long version:

Some bearing noise and steel shavings on my drain plug inspired me to finally tear down my 2008 FE550 after 210 hours. I found my main bearings were toast (as expected), with some light scoring on the piston and liner.

I'm inclined to reuse the liner as-is and replace the piston. For that, I need to size the bore. Since I don't have the right tool for that job, I went to the only engine machine shop in town and slipped them a fiver to measure it up. I was told that it was 3.932 inches.

When I got home I converted that over to metric (99.87 mm) and checked my shop manual which gives the size 1 liner spec as 100.000 to 100.012 mm. Something clearly didn't add up here, so I went back to the machine shop and asked them to double-check. They checked again, apologized for the error in the first measurement, and revised their number to 3.942 inches.

Again, I went home and checked the converted number (100.127 mm) against the specs. This time, it's way over even the size 2 liner maximum of 100.025 mm. At this point, I'm pretty sure the machine shop is not providing anything close to an accurate number.

I'm giving up on the shop measurement, and I'm wondering if anyone has any advise on how to proceed. I'm going with a ProX piston, so that leaves three options: 99.95, 99.96, or 99.97 mm. Is it reasonable to just go for the mid-sizer as a guesstimate?
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December 1st, 2017, 02:44 PM   #2
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If you are concerned about your cylinder being worn, you can send it to US Chrome and they will re-plate the cylinder and match it to the piston at whatever piston/cylinder tolerance you request. I had them do my 94 501.
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December 1st, 2017, 05:10 PM   #3
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How much did US Chrome charge you for that service?

I priced out re-plating here in Canada and it was only marginally cheaper than a new liner. ~CAD$350 re-plate (with 2x shipping) vs ~CAD$415 for a new liner.
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December 1st, 2017, 11:37 PM   #4
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Replating the liner with the likes of Nikasil, will last longer than the OEM liner. Just be VERY clear to the company doing it, that they MUST NOT grind anything off the edge of the liner, facing the head gasket!

Maybe mentioned already, but supply your piston (Prox is not the preferred choice from what I hear) to the replating company and tell them what piston clearance you want.
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December 2nd, 2017, 12:27 AM   #5
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with that bore measure id be thinking the liner might be oval its quite common

so I would measure it again but this time check for ovality
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December 2nd, 2017, 10:54 AM   #6
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Both directions were checked, both times, and there was supposedly no detectable ovaling. I might pop the old piston in the cylinder and check with some feeler gauges to confirm.
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December 2nd, 2017, 11:33 AM   #7
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US Chrome was $200 plus shipping. I also had them apply their coating to the piston skirt. They have a website.
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December 2nd, 2017, 03:05 PM   #8
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Originally Posted by VOR165 View Post
US Chrome was $200 plus shipping. I also had them apply their coating to the piston skirt. They have a website.
Can you provide website? Or phone number? Or are they just called US Chrome?
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December 2nd, 2017, 06:20 PM   #9
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http://www.usnicom.com/

Here is my thread, where you can see their work:

94 FE 501 Rebuild
Thanks from polska

Last edited by VOR165; December 2nd, 2017 at 07:48 PM.
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December 3rd, 2017, 07:27 AM   #10
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Originally Posted by fixbroke View Post
How much did US Chrome charge you for that service?

I priced out re-plating here in Canada and it was only marginally cheaper than a new liner. ~CAD$350 re-plate (with 2x shipping) vs ~CAD$415 for a new liner.
Was that quoted by by CVTech AAB in Thetford Mines Que.?
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