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Mahle cylinder boring

Posted: Sat Sep 09, 2017 5:22 pm
by Bsherrard
Anyone know a shop that can bore my original German Mahle cylinders to 96mm?? Not having any luck finding a place.

Re: Mahle cylinder boring

Posted: Sat Sep 09, 2017 7:21 pm
by Piledriver
European Motor Works or RIMCO.
Getting them packaged right is most of the battle.

Be aware you are not saving money going down that path, the new EMW jugs are also not bad from all accounts.
The potential advantage is the heat cycled/aged jugs should stay round better, as well as wear better..

Also note most motorcycle shops can bore/hone free standing iron jugs, or know a machine shop that can.

Re: Mahle cylinder boring

Posted: Sun Sep 10, 2017 5:19 am
by Bsherrard
Piledriver,
I will check with EMW and RIMCO. Thanks.
Good thought on the bike shops, didn't think of that.
Brook

Re: Mahle cylinder boring

Posted: Mon Oct 09, 2017 2:50 pm
by Bsherrard
Just a quick follow up. Neither EMW or RIMCO would do the cylinder boring. There is a local shop that does jet ski and motorcycles but they wouldn't do them either. Finally found a machine shop that will do them, they have done them in the past but it was a long time ago. They are going to have to fabricate a thrust plate to do the job. We will see how they turn out - might end up just going with the Chinese junk!
This is just crazy - I bet 20 years ago this was an everyday procedure!
Brook

Re: Mahle cylinder boring

Posted: Mon Oct 09, 2017 7:09 pm
by sideshow
Wow, I kinda expected RIMCO to fall off the planet due to all the in-house skill lost over the last few moves.
I also thought this was still a common procedure especially in the bike crowd.

So I guess it is just a matter of hours before the only person on the planet that can afford to repair a car will be Jay Leno.

Re: Mahle cylinder boring

Posted: Tue Oct 10, 2017 1:34 pm
by H2OSB
I have a set of those cylinders and considered both boring the 94s to 96s, and finding workable 94s for the 66mm crank(T1Cs...i think that's what it is), but in the end with Pile's good advice and considering the fact I'm a cheap ass, I decided to hold off to get set of EMW 96 Ps&Cs. Glad I waited...I ended up acquiring a 71mm crank when my son gave up on his T4 dreams.

H2OSB

Re: Mahle cylinder boring

Posted: Tue Oct 10, 2017 1:38 pm
by Bsherrard
I may end up going that route if the boring doesn't work out. I really prefer to keep the German Mahle's - they are nice cylinders!
I guess I could always splurge on Nickies, I mean hey...their only $2,760!!
Brook

Re: Mahle cylinder boring

Posted: Thu Oct 19, 2017 7:30 am
by raygreenwood
Call Roy at Mofoco. He may not be a type 4 full time mechanic.....but I will wager he has tools and experience including torque plates to hone cylinders.
Ray

Re: Mahle cylinder boring

Posted: Mon Oct 30, 2017 3:27 am
by Bsherrard
Ray -
thanks for the suggestion. I did find a local machine shop here in Orlando that is going to bore them. They don't specialize in air cooled so I am hoping for the best. I just got back from Germany - maybe I should have taken them over there and tried to get them done:)
Brook.

Re: Mahle cylinder boring

Posted: Fri Nov 03, 2017 11:36 am
by raygreenwood
The problems you are finding is why I cringe at the habits from the past 40 years...of simply removing worn out...but unbroken cylinders and throwing them in the trash. It was always said that re-boring was not cost effective.

Now...we have problems finding good cylinder castings.....and re-boring may now be the best option....but everyone threw away the castings. The real deal is making sure you have a torque plate on the machine that fits your cylinders. Ray

Re: Mahle cylinder boring

Posted: Thu Nov 23, 2017 6:33 am
by Bsherrard
Cylinders back from machine shop and look good and after all the waiting, it only cost $160.

Re: Mahle cylinder boring

Posted: Sun Dec 31, 2017 5:00 pm
by Bsherrard
thought I would update and close out this thread. As I mentioned, I was able to get my cylinders bored out by Revmasters Machine Shop in Orlando. They came out great. Here are some pictures after I cleaned them, media blasted the fins and painted with Rustoleum flat black thinned 20% with mineral spirits. So much better than what I can buy new (except of course Nickies which are in a league and price range all their own).
cylinders 2.jpg
Cylinders 1.jpg
Brook

Re: Mahle cylinder boring

Posted: Wed Jan 01, 2020 4:51 pm
by 914werke
Thanks for the follow up
So next question is Revco interested in doing more?
How many more, would it make it viable to receive a discount? How much?
At 160 + shipping its hard to compete with NEW castings from the usual sources.
While I understand the general reasoning for going this direction I dont agree all "Chinese" products are Junk ~

Re: Mahle cylinder boring

Posted: Thu Jan 02, 2020 2:09 am
by Piledriver
Revmasters Machine Shop in Orlando, Florida.

They probably had to make torque plates, and tooling/setup is usually 75-90% of a machine shops costs...
I would expect a large volume discount if you wanted to do more than 1 set..

Re: Mahle cylinder boring

Posted: Thu Jan 09, 2020 8:06 pm
by Bsherrard
914Werk I’m not sure if they would do more. This thread is two years old. They have done a few other things for me over the last two years

Brook