piston to cylinder clearance (2017)

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Because of the danger of these fancy pistons falling to pieces?
Fancy pistons? Those pistons have been used for decades as standard equipment in pre-Evolution Big Twins with great reliability. Even S&S supplied them with the 80 cu In and 84 cu in "road special" stroker kits when longevity was the main criteria and sane break in tactics would be employed. I believe the steel strut was cast in. I had a set of them in my 86 cu in Panhead for over 30 years.

piston to cylinder clearance (2017)
 
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The answer to the clearance problem is Nikasil cylinders or iron liners with an expansion rate closer to aluminum that allows closer tolerances. There is such an iron alloy for alum cylinder liners. Its difficult to find and it must be machined per application but its been used in a few English bikes with great success.

Can anyone name the alloy? This should be interesting.

Hint - Jim Comstock once machined a set of this special cylinder liner alloy from solid bar stock.
 
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Fancy pistons? Those pistons have been used for decades as standard equipment in pre-Evolution Big Twins with great reliability. Even S&S supplied them with the 80 cu In and 84 cu in "road special" stroker kits when longevity was the main criteria and sane break in tactics would be employed. I believe the steel strut was cast in. I had a set of them in my 86 cu in Panhead for over 30 years.

piston to cylinder clearance (2017)
How do those engines compare to a Commando in RPM and piston speed?
 
How do those engines compare to a Commando in RPM and piston speed?
With a 4.520" stroke at 5500 RPM and a rod ratio of 1.645:1, I would say piston speed in the Harley Big Twin is higher than an 850 Commando engine (3.50" stroke with a rod ratio of 1.679:1) at 7000 RPM.

I would think that side loading on the Harley piston would be considerably higher too.
 
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Avg piston speed would be very similar for both engines – the HD at 4143 ft/min, the Norton at 4083 ft/min.
 
Avg piston speed would be very similar for both engines – the HD at 4143 ft/min, the Norton at 4083 ft/min.
Perhaps I should have qualified the HD as having "slightly" higher piston speed, but yes similar.
 
5,500 rpm is much less than 7,000.

Fitting those steel insert pistons in a Commando would be a leap in the dark, unless people have done it already and will pass their experience on.
 
If you want tight piston to cylinder clearance then go for the line2line graphite coating. A .0015" coating on each skirt gives you a clearance of a thou or two. Since the graphite is a lubricant - any tight spots will burnish off without scuffing. The metal to metal clearance must remain the same as suggested by the manufacturer. I've been doing this for years and it works great. Pistons remain tight and rocking is reduced to a minimum. Piston life is extended up to double.

piston to cylinder clearance (2017)


For a few buck more you can dot the piston and still be able to measure the metal to metal clearance.

piston to cylinder clearance (2017)
 
If you want tight piston to cylinder clearance then go for the line2line graphite coating. A .0015" coating on each skirt gives you a clearance of a thou or two. Since the graphite is a lubricant - any tight spots will burnish off without scuffing. The metal to metal clearance must remain the same as suggested by the manufacturer. I've been doing this for years and it works great. Pistons remain tight and rocking is reduced to a minimum. Piston life is extended up to double.

piston to cylinder clearance (2017)


For a few bucks more you can dot the piston and still be able to measure the metal to metal clearance on installation.

piston to cylinder clearance (2017)
 
5,500 rpm is much less than 7,000.

Fitting those steel insert pistons in a Commando would be a leap in the dark, unless people have done it already and will pass their experience on.
But the piston speed will be slightly higher with the HD even at 5500 RPM. Rod angle is also slightly more in the HD putting more side thrust on the piston. As long as the piston does not expand to the point of seizure, the closer skirt clearance will put less stress on the piston.

The original post pondered why Norton didn't utilize, or at least explore the possibility of utilizing a long proven technology that allowed close piston clearance with a cast aluminum piston in a cast iron cylinder. How would that have been "a leap in the dark"? There have probably been millions of HD motorcycles built over the course of several decade that proved the reliability of this technology.

I never advocated anyone attempting this on their own.
 
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Parallel twins run a lot hotter than V twins in general.
I recently installed the supplied steel strut pistons from the RGM 920 kit. Similar to other Norton pistons, they are at .0045" clearance as specified by the supplier.

Glen
 
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