Cylinder wall repair

[69DAYTONASE]

What is the best way to repair a cylinder wall that was slightly gouged when the engine dropped a valve and the head of the valve broke off when it hit the top of the piston?
The block is .030 now. It appears the previous owner used silver solder to fill in the minor imperfections in a very small area at the top of the number 1 cylinder. The engine was run this way.
I would like to do something better and finish it off better while keeping the .030 bore spec.
Is there a better way to do this? I was thinking about cast iron spray welding, is there a way to rig up something to do this at home? The affected area is about the size of a dime. Thanks!

[fy469rtse]

If it were my engine , there's only one way to repair this properly ,
Good machine shop , sleeve it ,

[c00nhunterjoe]

A fresh block bored .030 will probably be chaeper then and repair you may be looking at.

[Challenger340]

Dunno about any type of welding with cast in a cylinder ?....  as invariably HEAT + CAST at temperatures sufficient for bonding has the undesired effect of transforming some of the Carbon involved into VERY hard, almost "diamond" like areas.
Such a small area done in a Cylinder ? methinks might be a bear to then Hone later ?

IMO,
Best fix is to sleeve the damaged hole.
* Make sure they "step" the sleeve @ bottom.... means leave a "lip" at bottom for the sleeve to sit down against.
* Surface the Block "Equal & Square" afterward to true up the decks.
* Try and keep the "interference" fit of the sleeve in the block to approx .0015" or so, to limit distortion on the adjacent Cylinders.

When a sleeve is punched into a block, unfortunately that "press fit" stress is transferred sideways to adjacent cylinders as well, distorting them out of round.
Very tough to then fix them back round and stay on the same Bore Size ?
Usually another .010" to next Bore Size is advisable to allow room to Hone the distorted adjacent Cylinders back to round.

[69wannabe]

Dunno about any type of welding with cast in a cylinder ?....  as invariably HEAT + CAST at temperatures sufficient for bonding has the undesired effect of transforming some of the Carbon involved into VERY hard, almost "diamond" like areas.
Such a small area done in a Cylinder ? methinks might be a bear to then Hone later ?

IMO,
Best fix is to sleeve the damaged hole.
* Make sure they "step" the sleeve @ bottom.... means leave a "lip" at bottom for the sleeve to sit down against.
* Surface the Block "Equal & Square" afterward to true up the decks.
* Try and keep the "interference" fit of the sleeve in the block to approx .0015" or so, to limit distortion on the adjacent Cylinders.

When a sleeve is punched into a block, unfortunately that "press fit" stress is transferred sideways to adjacent cylinders as well, distorting them out of round.
Very tough to then fix them back round and stay on the same Bore Size ?
Usually another .010" to next Bore Size is advisable to allow room to Hone the distorted adjacent Cylinders back to round.

That's very interesting and make's alot of sense!!!!! And in this case .010" isn't going to hurt anything!! Just be a .040" engine now.

[b5blue]

Would the cylinder clean up @ .060 over?