Can 406 Block Be Re-sleeved? - Ford Muscle Forums : Ford Muscle Cars Tech Forum
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post #1 of 5 (permalink) Old 02-19-2019, 08:52 AM Thread Starter
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Can 406 Block Be Re-sleeved?

The block in my 63 Gal 406 is an early 1963 cast C3AE-V 406 block. It is currently bored 60 over which I understand is the safe max bore. Question --- is this block re-sleeveable? Although the build is fresh (2017) if something should happen is another rebuild possible?

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post #2 of 5 (permalink) Old 02-19-2019, 09:45 AM
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Re: Can 406 Block Be Re-sleeved?

You would be money ahead by having a custom piston made at .065 to .070 over. A 406 will easily take that much additional bore . Rings are available in those sizes as well. Sleeving the block back removes a tremendous amount of original block material and severely weakens it.

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post #3 of 5 (permalink) Old 02-25-2019, 05:12 AM
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Re: Can 406 Block Be Re-sleeved?

Although I agree completely with Randy's post above, the next time around be sure to have it sonic checked first, but go with the minimal overbore you can, and determine that by measuring with a torque plate bolted on or from the bottom with a head bolted on. Nowadays it's affordable and easy to order pistons in almost any size. Often you will find a cylinder or two with a thin spot on early FEs (or many) which can be fixed by a sleeve or two in that hole, or offset boring.

Although it seems like the early solid lifter blocks tend to be decent, as said above, they still were not designed for that overbore, and I have seen absolutely no consistency in FE blocks in terms of cylinder wall. In fact I recently passed on an early solid lifter 390 bored to 4.13 because it didn't check, it was nice too, about 1200 in machining with cross bolts, square decking, etc and also had to swap a block on a 461 CJ build because although it was potentially usable, with the power and customer's "do it once only" budget, I didn't trust it.

The issue tends to be that a whole bank will be "up and over" if that makes sense, making some sides real thick and others thin after it is finish bored at the factory.

FYI, the concern is not with overheating, it's with (best case) poor ring seal due to a flexing thin wall, and (worst case) a split cylinder and the carnage that may or may not trigger. All that being said, my 489 FE, 427 based, has been together since 2006 with a .047 over piston. That block is named "lucky" with 3 sleeves, a repaired pan rail within the repair of an earlier pan rail window LOL I don't know the story of the block, it had a hard life and I never blew it up, but it's certainly "stress relieved" by now and has been happy for 12+ years

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post #4 of 5 (permalink) Old 04-11-2019, 06:50 PM
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Re: Can 406 Block Be Re-sleeved?

GT350HR has the right idea. I once had a 368 Lincoln block that had .100 over pistons.
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post #5 of 5 (permalink) Old 04-12-2019, 11:11 AM
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Re: Can 406 Block Be Re-sleeved?

For some particular reason people are in fear of a .005-.010 additional over bore ( or it could be honed) as if it somehow renders a block to the junk pile. Guys .005 more is ONLY .0025 of cylinder wall material removal , or about the thickness of a sheet of regular paper. That TINY amount of removal will NOT create overheating ( as Ross mentioned) NOR will it cause a cylinder wall crack. It WILL give a new bore finish for the piston to ride on and allow good ring seal. Boring a block to accept "thin wall" sleeves requires a .250 OVERBORE to allow the sleeve to be fit. That amount usually loses MOST of the original cylinder wall in several areas and hurts the "deck integrity" by losing SO much material. Unless a block is designed to use repalcable sleeves ( read aluminum block) DON'T DO IT.

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