Block boring is a fundamental machining process that enlarges an engine's cylinders to a precise new diameter, typically to accommodate oversized pistons during an engine rebuild. This procedure is necessary to correct for wear, tapering, or out-of-round conditions that develop over time, or to repair damage such as scoring on the cylinder walls. Restoring the integrity of the cylinder bore is crucial for re-establishing compression, controlling oil consumption, and maximizing engine power.

The process is followed by honing, a final finishing operation that is essential for performance. Honing uses abrasive stones to produce an extremely fine surface finish on the cylinder walls, creating a specific cross-hatched pattern. This pattern is vital for retaining a thin film of lubricating oil, which allows the new piston rings to seal properly against the cylinder wall, ensuring optimal compression and a correct 'break-in' period for the rebuilt engine.

Block Boring

Engine pressure testing, specifically through a cylinder leak-down test, is a highly accurate diagnostic procedure used to determine the sealing integrity of an engine's combustion chamber. Unlike a simple compression test, a leak-down test pressurizes each cylinder with compressed air and measures the percentage of air that escapes. This allows us to precisely identify hidden issues without major disassembly, pinpointing the exact source of compression loss.

By listening for the escaping air, our technicians can accurately diagnose the problem. Air heard from the oil filler cap indicates worn piston rings or cylinder walls; from the air intake points to a leaking intake valve; from the exhaust suggests a faulty exhaust valve; and bubbles in the radiator coolant reveal a blown head gasket or a crack in the cylinder head or block. This non-destructive test provides a clear and reliable assessment of engine health.

Engine Pressure Testing

Crankshaft grinding is a precision machining process used to restore worn or damaged crankshafts to their original factory specifications. This critical procedure involves carefully grinding the main and connecting rod journals to achieve the perfect size, roundness, and surface finish. Proper grinding is essential for any engine repair or complete rebuild, as it guarantees correct bearing clearance, smooth rotation, and the overall longevity and reliability of the engine.

At Amar Engineering Works, we specialize in heavy-duty crankshaft grinding and are the sole provider of this service for large-scale applications in South Gujarat. Our advanced machinery allows us to handle massive components, including crankshafts up to 11 feet in length and weighing over 3 tons. Using high-grade grinding stones and meticulous polishing techniques, we remove all surface imperfections like pitting or scoring, ensuring your engine's core operates with unparalleled precision and durability.

Crank Shaft Grinder

This service focuses on restoring the critical rotating and reciprocating components of an engine's lower end. Connecting rod reconditioning is vital for addressing wear on both the big end (crankshaft side) and small end (piston pin side) bores. We precisely resize these bores to eliminate out-of-round conditions, replace worn bushings, and ensure the rod is perfectly straight, preventing engine noise and potential failure.

In conjunction with rod service, we specialize in the fabrication of custom bearings, particularly through processes like Babbitting and metallizing. When standard bearings are unsuitable due to unique size or load requirements, we manufacture bespoke solutions designed for optimal performance and durability. By combining expert connecting rod reconditioning with custom bearing fabrication, we deliver a complete, integrated solution for a robust and reliable engine assembly.

Fabricating and Metallizing of Bearing 

Line boring is a specialized machining process designed to restore the perfect alignment of main bearing bores in engine blocks and other heavy industrial machinery. When these bores become worn, distorted, or misaligned, it can lead to excessive friction, premature bearing failure, and catastrophic engine damage. The primary goal of line boring is to create a perfectly straight and concentric tunnel for the crankshaft or camshaft, allowing it to rotate freely and efficiently as intended.

Our process utilizes a specialized machine with a long, precision-guided boring bar that is passed through the existing bores. We carefully remove material in small, consistent cuts across all main bearing housings and caps simultaneously. This meticulous technique ensures every bore is perfectly collinear and machined to the precise diameter required for new bearings or bushings. The result is a fully restored engine block foundation, critical for a smooth-running and durable engine.