The block "deck" looks like this:

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Sorry, I neglected to see the aluminum part in the title.

Well, you could tip it over on a flat surface then pour HardBlok in it to create a false deck, maybe 1-1/2" or so. Then skim cut if all flat. Or maybe that's already been tried...

Or....add a 3/4" plate on top, then sleeve the whole affair to get a good bore. Then, use some really long rods to make up the difference.

I thought you get a better head gasket seal if the center iron cylinder is a little bit higher than the rest of the block.

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Ed
64 Valiant 225 / 904 / 42:1 manual steering / 9" drum brakes

The simple solution to me would be a CNC program to make a press fit plate. the fitment could be uniformed with a cnc cut of .020-.030 thou around all of the mating surfaces on the block. press it in and bolt on a head. the welding method that DD tried was way over thought IMO.

This is the "Honda" method I mentioned. It's simple in concept. Would you like to bid the job?

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Joshua

I certainly would if I had a dog in the fight. I could make it all at my work (once we get back, lol)

We'll just have to add a new block on the want list. That "Honda" technique might be worth a try.

Got it.
I guess decking the block and cylinders without support could be catastrophic.
With today’s technology for metal machining including 3D printing, a tight toleranced filler plate is more likely at an affordable price then even just 3 years ago.
I know some engineers at a local startup here in Silicon Valley are getting great success with metal 3D printing I could talk to. I wonder how much variation from block to block there is.

Cast iron baby, Cast iron!!

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2 Mopars come with Spark plug tubes. One is a world class, racing machine. The other is a 426 CI. boat anchor!

12.70 @ 104.6

Rick likes cast Iron, It's what he knows, it's what the "magic" walking/ hiding Hyperpak Manifolds were made of.

Now the boring stay put hyperpak intakes were made of AL.



Greg

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With how little of a clean up cut I'd run ( probably .050 around the inside of the block, .025 around the cylinders) hopefully the plate could "correct" any shift. .375 6061 for the plate should be more than sufficient, and cut the block at .400 deep to allow for a follow-on decking.

the block program could be written in 2-7 different steps to allow for locating centers on the bore to factor for shift.

If the head could be mirror relief cut to the cylinder sleeves inside and outside diameters and O-ringed, you could lock the cylinder wall into the head for rigidity. The block would need to be decked and the cylinders left a little taller than the casting. Some tolerance would be needed, and how much would need to be known before cutting.

What did he say???

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Hyper_pak

What is the weight savings on the aluminum block?

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2 Mopars come with Spark plug tubes. One is a world class, racing machine. The other is a 426 CI. boat anchor!

12.70 @ 104.6