How to Cut Cylinder Blocks

Cutting your own cylinder block is a somewhat challenging task.

A cylinder block is one of the biggest engine components. It consists of a set of pistons and cylinders on the upper part, while the lower section contains the crankshaft. Cylinder blocks can be made from nickel or chromium alloy. They can also be created in one piece, from iron or aluminum. The most common cylinder blocks engines are made from aluminum. These are cast around iron cylinder bore liners. Cylinder blocks with aluminum alloy surfaces have been found to be more durable than other cast metal. If you are the type who loves to tinker with automobiles and engines, learning how to cast and cut cylinder blocks is a good project to work on.  

Things You'll Need

• Cylinder block mould
• Gloves
• Protective mask
• Welsh plugs
• Sand
• Molten iron or aluminum
• Water and hose
• Electric drill

Instructions

1. Suspend the core in a container with a liner that is similar to the shape of the engine block’s surface. This container acts as the core box where the cast iron or aluminum will be held.  

2. Secure the binders in place to support the core box. The same binders will also hold the sand grains together during the sand casting process.

3. Pour the molten aluminum or iron onto the core box. Make sure that you are wearing heavy duty gloves and face mask before doing so. The hot liquid metal will begin cooking the sand inside the core container.  

4. Wait for the sand to cool down before shaking the casting. The cool temperature causes the sand to loosen up inside the container.

5. Wash the sand away with water, aiming through the core holes. This will leave the finished cast of cylinder blocks. Remember to thoroughly remove the sand from all ends of the cylinder mould. The holes created during the process will be reserved as spaces for lubricants and cooling engine parts. Seal the holes using welsh or core plugs.  

6. Begin the process of cutting holes in the finished cylinder blocks.  Bore holes using an electric drill. The cylinder blocks are now ready to be attached to an engine.

Tips & Warnings

• Use a metal cutting machine for heavy duty casting projects.

• Take the necessary precautions when handling melted metal.  Make sure your suit and gloves do not have holes in case there is spillage.

References

• Automotive Engines: Diagnosis, Repair and Rebuilding; Tim Gilles
• Engine Builder: Common Mistakes to Avoid When Resurfacing Cylinder Heads & Blocks