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Sorry Tale of Cylinder Barrel.

Hello again readers and contributors to this fine forum.  Some several years ago I ended up with a worn-out cylinder barrel on a Dynamo Dominator 99 that I had used for many years.  The bore was on plus sixty thou and was very sloppy so it was time to replace it.  Being a obsessive hoarder I was reluctant to throw it away, and as there were no broken fins and the cam follower bores seemed satisfactory I kept hold of it - intending sometime to get it re-sleeved.  A chance meeting with a technician that I knew at British Aerospace ended with the barrel resplendent  with a good coating of hard chrome applied to the worn-out cylinders.  The process was used to repair worn out aircraft hydraulic rams and such things and the argument went along the lines that with cast iron rings it should last for another hundred thousand miles, at least ??   Of course, with hindsight I should have asked the technician to get it machined as well but as I was only at that site for a few days I did not.  Recently I found the barrel and decided it was time to use it on a dynamo Model 77 engine that I'm building. I asked around the bazaars and no-one wanted to do it so I took it to another engineer who has done rebores for me in the past.  He said that it would need special hard stones and he spoke to his supplier (Delapina) who provided two sets.  One for boring and one for honing ?   So, as you've probably guessed, the stones would not touch the surface.  After more phone calls the barrel was sent to another workshop that specialise in cylindrical grinding all to no avail.  Eventually the block ended up with a workshop that have concluded it is too difficult to grind and suggest that they get the hard chrome removed  and replace it with a ceramic coating that can be machined to fit my pistons.  All this for the bargain price of £1400 (plus VAT of course).   So now the barrel is on its way back to me still wearing its hard chrome vest and my super project is no further on.  After a good deal of cash and a few bottles of scotch I am in a quandry of where to go with this.  Sleeves are available but the hard chrome would need to be stripped first and how and who would do that ?  If any of you out there can think of my next cunning moves please let me know via this forum or privately.  I await your inputs with interest  and a little trepidation.  Regards, Howard 

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Howard, you need fine finish bore (Gun bore drilling) specialists - the routine cylinder barrel honing firms are not good or specialised enough for the chrome. Mind you, it will cost, I would expect to pay around £70-100 + for the hone depending on how much they need to remove. 

You would have a very good barrel once done though.  

I would have thought that a decent chrome plating shop would be able to strip the existing plating off. They do this regularly prior to restoring components . 

George

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I seem to remember that Series 1 Landrovers had chrome plated bores (presumably other vehicles of that time also)... would LR restorers know more about it?

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Thanks to you all - I shall investigate gun restorers and LR specialist restorers.  I am not sure that chrome electro-plating processes for decorative work is quite the same as for hard chrome but I will check to see whether or not the reverse process is possible without too much contamination of their electroyte. Cheers, Howard

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Look up Langcourt, somewhere near weston-super-mare.

They will strip the chrome and re-plate with nikasil for a very reasonable £140 ish

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Howard,

If your cylinders are just hard chromed, you could experience issues due to inadequate lubrication. 

Hard chroming cylinders for piston engines can be problematic.  I was involved with the result of a salvage process for Bristol Pegasus radial engine cylinders, where simply hard chrome had been applied.  The piston rings only lasted for about three hours due to inadequate bore oil retention - pure hard chrome cannot hold enough oil and using cast iron rings alone is not effective.  Hard chrome for aerospace piston engine cylinder applications is generally applied using a 'channel chrome' process, whereby the electric current is reversed after plating, creating fine cracks in the chrome surface that then act is oil reservoirs.

The Pegasus cylinders are long stroke and relatively wide bore (5.75"), but even smaller flat four Lycoming type cylinders would suffer with pure hard chrome, so I would be cautious about simply finding someone to hone the bores.  A really coarse hone might provide enough oil retention, but potentially auto the detriment ring life.

Something to bear in mind anyway.

Regards,

Andy

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Thanks Andy - If I eventually find a specialist with experience of hard chrome on cylinder bores I will broach that subject.  If I don't,  the hard chrome has to be removed..........Ho hum .  Regards to all, Howard

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Hello again fellow readers.  I feel sure that you'll all be ready and eager to read my next instalment of my hard-chromed cylinder bores.  So,  I received back my barrel unscathed, still resplendent with its black powder coating, all its fins and sadly with its hard-chrome bores.  If you recall three engineering companies have now examined it to either rebore it, re-sleeve it or remove the chrome, all to no avail.  So following a long conversation with an expert chromium plater at the last VMCC Jumble of the season off it went again for an electro-chemical removal of all the hard-chrome.  Some days later I was asked to attend a ceremony where the 'Last Rites' for the barrel were read.  The electro-chemical process had expertly removed the mating surfaces for the cylinder head and crankcases.  It had also totally dissolved the cam-follower bores, most of the threads and ruined the locating holes for the crankcase studs.  The hard-chrome bores were of course hardly touched.  Except where the gentleman concerned had run over them with a grinding wheel.  Ho hum . I even had to pay for the process.  Treat all this as a warning.  Hard chrome is really not the best addition to a worn out iron barrel. 

So if any one wants a dynamo 600 engine minus a barrel now is your chance.  The bottom half of the engine is complete and begins with a pair of unnumbered (replacement ?) crankcases from the early 1950's.  The dynamo crankshaft  is a 'rare now' 600cc version with big-ends 0.010 inch undersize and a pair of later 88 con-rods.  The cam has little wear. The main bearings are sound with a brass-caged drive side roller and a standard 7-ball on the timing side. The timing gears, pinions and chains  and oil pump are fitted and there is a  Lucas 18D2 distributor in place.  The timing cover is the early type with the brass oval disc.  The broken barrel is good only as a door stop or replacement fin provider.  A complete set of radiussed cam followers, a set of 4 X 99 pushrods and a pair of Standard bore 650 pistons are with it to fit in a replacement barrel.  The cylinder head is a complete late big-fin type from a 99SS.  The engine when completed would make a lively upgrade to a tired Model 7 but could just as easily be used in a Model 88, Model 99 and a Nomad.  I will be inserting a Classified in For Sale section soon.

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My 99 basket case engine came with  chrome bores but had rusted badly in storage. Paynes of Eynsham near Oxford removed the plate and re-sleeved for me.Worth a try if  you are not too far away.

Hi - I am interested in your barrels as fin donor if you are interested in selling - I am in the USA so shipping cost may be prohibitive. If you are interested let me know what you require for them and then we can explore shipping options - Thanks - Richard 

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