How thin can you machine an Aluminum cylinder and still be safe?
I realize the cylinder is coated with "Alusil"or "Silitec"; all brand names for hypereutectic coating.
The bore of the block at largest is 97mm. I'm aiming for 102mm.
Thanks for any replies
Hary Gahtoe

Have a look at Porsche 928 sites, they have al bores.

Other issues are finding a cylinder head gasket for the larger bore and having enough gasket between cylinders.

It may come to the point of installing steel wet liners.

What bores did this engine come in and what years / cars was it in?