I want to mill the tops of some T aluminum pistons for an experimental project. What do you think the minimum thickness of the piston top could be milled to and still be safe?
You can have pistons made in any shape and size, here are mine for the BBR Chris Egsgaard engine as made by Ross with the Miller Tubular Rods.
Yeah Frank, you can get anythng if your name is on the Forbes 500, but some of us have to "poorboy" it.
Contact me off list and will give you the best consel I can
Terry, Ross made those slugs for me and left an inch and a half of meat on the top so we could mill them. They were actually not too expensive. I got a job mowing lawns and a paper rout for three months and paid for them. Here is a picture of the blanks before machining
I made about $5 a pop mowing yards and $90 a month throwing papers, so they must have been in the $300-$400 range (not counting for inflation, of course).
Les will give some good advice. You could also get a modern piston from the junk yard and check its thickness.
When I worked turbo-normalizing Aircraft engines in the 1960's we burned holes in pistons when we ran too lean. The rule was that there were no turbos until we had full throttle. But in an airplane you can load the prop and hold R.P.M. where you want it usually 2650.
I know that the high compression aluminum pistons on the market can not be used with anything but stock heads. what I want to do is mill the tops of a set of hi-comp pistons to fit the combustion chamber of a Waukesha head. I am going to measure the thickness of an aftermarket aluminum piston and compare it to the thickness of the hi-comp piston to see if there is enough to mill. if not, I can always mill a little of the top of the combustion chamber in the head.
I will say 1/8" IF the area isn't too big and depending on where on the piston head it is located. I know not much use to you.
I have thought about what you are trying to accomplish. I would look at modifying the head to fit the pistons. Try for a clearance of about 1/16"assembled (if the piston just barely clears without a gasket you would be fine)