Bolt-on cylinder kit and method for increasing the displacement of an engine
A cylinder for a V-twin engine includes a section of steel tubing cut to a length. The section of steel tubing includes a first portion having a first wall thickness and a second portion having a second wall thickness less than the first wall thickness. The second wall thickness is less than 0.050 inch. The section of steel tubing includes a first ribbing pattern on an outer surface, within the first portion, and a second ribbing pattern including multiple ribs formed on individual ribs of the first ribbing pattern. A cast body is provided on the first portion of the section of steel tubing so that the section of steel tubing is fixedly secured within the body to form a cylinder sleeve defining a cylinder bore. The second portion having the second wall thickness extends from an end of the body to be received within a bore of a crankcase.
1. A cylinder for a V-twin engine, the cylinder manufactured by a process comprising:
providing a section of steel tubing;
cutting the section of steel tubing to length;
machining the section of steel tubing in a subtractive process, including
forming a first portion having a first wall thickness and a second portion having a second wall thickness less than the first wall thickness, wherein the second wall thickness is less than 0.050 inch, and
forming a first ribbing pattern, including a radially outward protruding rib, on a radially outer surface of the section of steel tubing within the first portion, and forming a second ribbing pattern on the radially outer surface of the section of steel tubing within the first portion, wherein the first ribbing pattern is a larger, primary ribbing pattern and the second ribbing pattern is a smaller, secondary ribbing pattern whereby multiple radially outward protruding ribs of the second ribbing pattern are provided within the radially outward protruding rib of the first ribbing pattern; and
casting a body onto the first portion of the section of steel tubing so that the section of steel tubing is fixedly secured within the body to form a cylinder sleeve defining a cylinder bore, wherein the second portion having the second wall thickness extends from an end of the body to be received within a bore of a crankcase.
2. The cylinder of claim 1 , wherein the body includes an exterior surface having a plurality of fins.
3. The cylinder of claim 1 , wherein the body is solid, having no internal voids or cooling jackets for cooling liquid.
4. The cylinder of claim 1 , wherein the body further includes a flange proximate the end, the flange defining a surface configured to about a surface of the crankcase, and a plurality of mounting holes extending from the surface through the body.
5. The cylinder of claim 1 , wherein a diameter of the cylinder bore is greater than 3.948 inches.
6. The cylinder of claim 1 , wherein a diameter of the cylinder bore is about 4.000 inches.
7. The cylinder of claim 6 , wherein the outer diameter of the second portion is about 4.068 inches.
8. The cylinder of claim 1 , wherein the cylinder sleeve is constructed from SAE grade 4140 steel.
9. The cylinder of claim 1 , wherein the second wall thickness is less than 0.040 inches and greater than 0.025 inch.
10. The cylinder of claim 1 , wherein the second wall thickness is between 0.033 inch and 0.035 inch.
11. The cylinder of claim 1 , wherein at least one of the first and second ribbing patterns is helical.
12. The cylinder of claim 1 , wherein the first and second ribbing patterns are formed in intersecting helical patterns having opposite axial components in a given circumferential direction.
13. A cylinder for a V-twin engine, the cylinder comprising:
a section of steel tubing cut to a length, the section of steel tubing including
a first portion having a first wall thickness and a second portion having a second wall thickness less than the first wall thickness, wherein the second wall thickness is less than 0.050 inch,
a first ribbing pattern, including a radially outward protruding rib, on a radially outer surface of the section of steel tubing within the first portion, and
a second ribbing pattern on the radially outer surface of the section of steel tubing within the first portion, wherein the first ribbing pattern is a larger, primary ribbing pattern and the second ribbing pattern is a smaller, secondary ribbing pattern whereby multiple radially outward protruding ribs of the second ribbing pattern are provided within the radially outward protruding rib of the first ribbing pattern; and
a cast body provided on the first portion of the section of steel tubing so that the section of steel tubing is fixedly secured within the body to form a cylinder sleeve defining a cylinder bore, wherein the second portion having the second wall thickness extends from an end of the body to be received within a bore of a crankcase.
14. The cylinder of claim 13 , wherein the cast body includes an exterior surface having a plurality of fins.
15. The cylinder of claim 13 , wherein the cast body is solid, having no internal voids or cooling jackets for cooling liquid.
16. The cylinder of claim 13 , wherein the cast body further includes a flange proximate the end, the flange defining a surface configured to about a surface of the crankcase, and a plurality of mounting holes extending from the surface through the cast body.
17. The cylinder of claim 13 , wherein a diameter of the cylinder bore is greater than 3.948 inches.
18. The cylinder of claim 13 , wherein a diameter of the cylinder bore is about 4.000 inches.
19. The cylinder of claim 18 , wherein the outer diameter of the second portion is about 4.068 inches.
20. The cylinder of claim 13 , wherein the cylinder sleeve is constructed from SAE grade 4140 steel.
21. The cylinder of claim 13 , wherein the second wall thickness is less than 0.040 inches and greater than 0.025 inch.
22. The cylinder of claim 13 , wherein the second wall thickness is between 0.033 inch and 0.035 inch.
23. The cylinder of claim 13 , wherein at least one of the first and second ribbing patterns is helical.
24. The cylinder of claim 13 , wherein the first and second ribbing patterns are formed in intersecting helical patterns having opposite axial components in a given circumferential direction.