How to Make a Small Engine Cylinder

Here we have a tour of the Hyway manufacturing process for small engine cylinders.

1. This "How to Make a Small Engine Cylinder" video slideshow is brought to you by HywayUSA.com.

2. There is a sand-like cast of the hollows and ports etc., placed in the midst of a cylinder mould.
Hollow parts of internal channels and core will be plugged by this sand-like cast.
It will be removed after the metal is poured around and over it.


3. Mould Around Sandy Core
Close the mould around the core, ready to pour molten aluminum over it.

4. Fill The Mould
Pour in the hot, liquified aluminum.
It covers the sand core and fills all gaps.

5. Cool
Let the newly poured molten aluminum cool.

6. Open the Mould
Once it is solidified and cooled, we can open the mould to see the new small engine cylinder.

7. Remove Cylinder
It is still hot so we lift this newly made cylinder out of the mould with tongs.

8. Remove Excess Sand Fill
Our CNC machinist then can remove the excess sand-like material from the core of the cylinder.

9. CNC
We drill the holes out of our little engine cylinder.

10. Honing
The small engine cylinder has to be honed.

11. Nikasil Plating
We "coat" the cylinder bore with Nickel Silicon Carbide, which is harder than steel.
A.K.A. Nikasil.
It improves heat conductivity and engine tolerances.
It's what Formula race car engine cylinders have in them.
Electroplated onto the cylinder bore.

12. Small Engine Cylinder Inspection
The final step;
Inspect the new small engine cylinder to make sure it's to specifications.