JDana2@aol.com wrote:

 Paul:   nikasil coatings are put on by aircraft cylinder remanufacturers .
It isn't this process I am concerned about It ti the warpage , sealing and
cooling of the housings.The design of these pieces becomes more critical than
the wear coatings!  JIM DANA

Right on Jim. Jim Mederer at Racing Beat has been working ten or fifteen
years on the project. Start by milling the cast iron end and
intermediate 
housings to see how Mazda routes the water flow.

endhou1.jpg

The complexity of these end and intermedaite housings suggest
that it is a bad idea to run the engine plugs up. Lots of nooks
and crannies for steam pockets to form.

The other problem you are going to run up against is shrinkage
of the aluminum housing when they get too hot  because the steel 
tension bolts holding the engine together expand at a lower rate 
than the alloy housings. 

I hope you are rich :-)

BTW the Mazda four rotor engine that won Lemans had aluminum end
and intermediate housings. Francesco Ianettie told me a four
rotor is going for $100,000 if you can find one for sale.

Paul Lamar
 
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