Piston Sleeve Replacement

Hello fellow boaters-

I have a 1995 60hp Evinrude with a bad piston and sleeve. I removed the sleeve so a new one could be put in place. When removing the sleeve I accidentally put a severe scratch on the cylinder wall. One friend of mine said the block is useless now and another says it is no big deal because the new sleeve will cover the damaged area. Before putting in the new sleeve a couple of opinions from you guys would be a great help. Am I doomed or not. I feel it will be OK.

Thank you for your time and responses.

Cheers,
GB

Re: Piston Sleeve Replacement

If the scratch is in the aluminum no big deal as you can install a thicker sleeve(up 1/8 inch). I hope you have a machine shop as this is really not a DIY repair as sleeve needs certain interference clearance with block and you will have to mill sleeve flush with block.

Re: Piston Sleeve Replacement

Curious as to how you removed the sleeve?When we resleeved,the block neede to be heated

Re: Piston Sleeve Replacement

Mikesea-

Try not to cringe to hard when I tell you how I got it out........I used a metal hacksaw blade to score the sleeve and then used a hard rubber mallet. The sleeve collapsed and popped right out. But when I hit it one time the sleeve put a nasty gouge in the block. The reason I did this was I am in Key West and I can not find anyone to resleeve in the Keys.......I was told to send it to Flagship Marine in Punta Gorda. I am a marine engineer and figured I would give it a try myself to get the sleeve out and replace it. If I ran into problems I would send it out, so have I run into a problem? When I put in cutless bearings on I freeze them and slide them in would a brass hammer and brass plate. Can this approach be used to put the sleeve back into the block?

Where are you in the Keys? I would be happy to send it to you.

Re: Piston Sleeve Replacement

If the gouge is nasty enough, couldn't the gouge be welded, then the weld area machined or bored to size?

Worse case, filled with JB weld?

Just thinking out loud.

I like the welded and bored out idea better.

If you have access to a milling machine, the sleeve could be milled flat to the deck. Otherwise, I don't know how the head would seal against the gasket.

Re: Piston Sleeve Replacement

My first idea was JB weld and mill corretly.......I have a pretty good shop to work out of but not exactly designed for doing a sleeve repair. Some else told me there needs to be a slight gap between the sleeve a block wall, this does not make sense to me.

If it all goes sour then it will go off to the proper shop but I thought I would give it a try.

Wish me luck and any advice would still be greatly appriciated!

GB

Re: Piston Sleeve Replacement

Hey guy,Im in Islamorada,I got a guy at Mile Marker 92 does the best work in the Keys.I'll send you a private message