Having block sonic thickness tested, need a temp donor 1.6 block

[rabbid79]

Hi, after lots and lots of searching/calling, I finally found someone in Utah with the equipment to test the cylinder wall and deck thickness of my 2.0 TD 5-cyl block.  I'd like to install 80mm pistons in it, but need to have it checked first.  While I'm at it, I can also take a 1.6 block down to be tested if someone is willing to lend me one(in Provo Utah area).  I know some people have expressed interest in installing the larger pistons in the 1.6 blocks, but, as far as I know, it's still unknown how thick the cylinder walls are.  If someone actually knows this, great, I won't bother.  Otherwise I'll have both blocks checked, and then we'll know.

[rabbid79]

Thanks Andrew, that's the thread I was talking about.  I didn't follow it through to the end and realize that the walls had been tested on the 1.6 block.  Guess it's a mute point.  Wish me luck on the 2.0 block.

[Rabbit TD]

It sounds like an interesting project to me.  I would be most concerned though that even if you know the thicknesses in those places would be what would be considered safe for that particular engine itself.  What works for a 1.6 might not be safe for the 5 cyl. unless you can find some information from someone who has done this before that is a reliable source.  Just torquing the head puts a lot of stress on the block.  Years ago I saw an article about how easily a block can flex.  They had a small block Chevy bare block and put an inside dia. measuring tool in one of the bores screwed out just enough for it to stay put and just kind of hugged the block and the mic. fell out.  I've always wondered if it was actualy true as I've never tried it myself  but maby one of the machinist types here could verify it or not.  I just feel that unless you know it has been sussfully done before you might be gambling a lot but that's also what they call a Pioneer too isn't it and I hope it works, I'd like to see and hear it and wish you luck.    

[rabbid79]

Thanks.  I don't know of too many people that have modified the 2.0 TD, so I am pretty much on my own here.  I'm not joking here when I say that the 5 cylinder weighs a lot more than 25% more than the 4 cylinder.  I would guess it weighs 50% more.  I'm hoping that some of this extra meat is in the cylinder wall area.  The 5-cyl blocks also seem to have a lot more webbing, so this could contribute some to the weight increase as well.  There are guys out there pushing 1000HP with 83.5mm bores on the gassers, but I realize that my block is a different casting, and can't necessarily by bored to this extent.  I'm just hoping the cylinder walls are thick enough, and it's worth the $35 dollars to find out if a relatively cheap and easy ~10% displacement increase is in my future.