deviousKA wrote:I would say 91mm is far beyond the limit that you would want in a boosted application. Main point of interest in the diagonal cooling passages that run in between bores, from the deck down. Where these passages cross the cylinders is the thinnest point of the entire cylinder wall. You will have take hot spotting into huge consideration, thin material + heat = bad. In my opinion I dont think you should venture into enlarging the bore any more than you need to, 91mm is to far.
I might have some information that would interest you though, regarding your stroker plans. Available in 90.2mm bore, is a great variety of affordable off the shelf forged pistons. These pistons are designed for the ford modular v8/10 engines (4.6, 5.4, 6.8 triton). I say these may interest you because of their compression height (or compression distance) is a few mm shorter than ka24 (4.6l=31mm KA = 34mm) and would be well suited depending on your rod configuration. Your going to need to run a piston with a shorter compression height, this will help with the rotating assembly characteristics allowing your to run as long of rod possible. This will also keep the piston lightweight. You can pick up a set of these modular ford v8 piston in aftermarket forged (ross, diamond, probe, etc.) for half of the price of an import forged piston, or less.
But before you were to get set on pistons, you will need to find an appropriate rod. SBC (small block chevy) has a good variety of rod lengths (oem and aftermarket) and most of these run a 2.1" journal (ka=1.96"). These can be fit, but will require extra material around the entire journal as well as some added to narrow the journal. All good things to make your machinist unhappy.
You could probably find a domestic V8 rod with a smaller journal, as the racers over here have been playing around with that a lot lately, but journal width is equally important. Most of the older V8 run very large diameter journals (2.1"+), so you will want to look into more modern engine, such as the modular ford v8's and some of the newer chevy ohc. Ebay is your friend.
If anyone else is reading this and gets hip to those cheap modular ford v8 pistons thinking they can make them work in their ka (like for a turbo application). Ask me and I will explain why they cannot be used. These would only be useful in a custom rotating assembly where the characteristics can be manipulated to bring them up to top deck. Quench is your friend, but can turn on you . If more clarification is needed, just ask.
Thanks for that gabe, you never cease to amaze!
I'm awaiting some pricing on 89.5mm Arias KA24E specific pistons; from what you've told me i'm hesitant to go with a larger bore now, as KA blocks are not as readily available and as cheap as in the states.Last thing i want to do is blow chunks out of the block
Ideally i'm aiming for 2.6 L final capacity, which can be achieved with the aforementioned 90.2mm bore and a 102mm stroke.
I really have no problem with a reduced limiter if need be, as this engine will be in my track only car.