Engine Mechanical Topics Discussion for motor builds, cams, head work, stripped bolts and other engine related issues. The good and the bad. If it goes round and around or up and down, post it here.

Case Boring....

Thread Tools
 
Search this Thread
 
Old Aug 28, 2022 | 07:57 AM
  #1  
98hotrodfatboy's Avatar
98hotrodfatboy
Thread Starter
|
Seasoned HDF Member
15 Year Member
Liked
Loved
Top Answer: 5
Joined: Mar 2010
Posts: 21,024
Likes: 7,549
From: Poolville
Default Case Boring....

I am currently running an S&S case and crank@96". I would like to know what is the maximum size I can have the cases bored to? Looking at possible 116"... 4.0" x 4.625". If that's not possible what would be? The case in question is the one shown below.. Thanks..


 
Reply
Old Aug 28, 2022 | 11:55 AM
  #2  
Max Headflow's Avatar
Max Headflow
Seasoned HDF Member
Joined: Dec 2005
Posts: 19,830
Likes: 7,968
From: poway
Default

I believe the biggest bore is about 3 11/16 inch.. The problem is that the studs are too close to the bore and there isn't any gasket surface left if you go bigger. SnS engine cases that support 4 inch and 4 1/8 bore have case deck raised 1/2 inch and different cylinder stud spacing..
 

Last edited by Max Headflow; Aug 28, 2022 at 12:04 PM. Reason: 3 11/16
Reply
Old Aug 28, 2022 | 12:12 PM
  #3  
Max Headflow's Avatar
Max Headflow
Seasoned HDF Member
Joined: Dec 2005
Posts: 19,830
Likes: 7,968
From: poway
Default

I was wrong.. You'll probably have problems finding cylinders..

https://www.axtellsales.com/Evo-Big-...eries-pistons/

 
Reply
Old Aug 28, 2022 | 12:57 PM
  #4  
smitty901's Avatar
smitty901
Seasoned HDF Member
Veteran: Army
15 Year Member
Liked
Community Favorite
Joined: Feb 2008
Posts: 22,998
Likes: 11,439
Default

That is how so many EVO's got trashed.
 
Reply
Old Aug 28, 2022 | 01:05 PM
  #5  
Max Headflow's Avatar
Max Headflow
Seasoned HDF Member
Joined: Dec 2005
Posts: 19,830
Likes: 7,968
From: poway
Default

The SnS cases are better but boring out bigger than 3 5/8 tends to be prone to leaks..

Wana go faster? Better heads? more compression? 96 ci with NOS? Yank the motor and install a 113 or 124

 
Reply
Old Aug 28, 2022 | 01:49 PM
  #6  
98hotrodfatboy's Avatar
98hotrodfatboy
Thread Starter
|
Seasoned HDF Member
15 Year Member
Liked
Loved
Top Answer: 5
Joined: Mar 2010
Posts: 21,024
Likes: 7,549
From: Poolville
Default

Yeah I'm not totally sure about the 3 5/8" cases.. I do know that S&S does make a different case for 4.0" bore and larger.. might be the way I go.. And then the pistons and cylinders..
 
Reply
Old Aug 28, 2022 | 01:55 PM
  #7  
Max Headflow's Avatar
Max Headflow
Seasoned HDF Member
Joined: Dec 2005
Posts: 19,830
Likes: 7,968
From: poway
Default

Originally Posted by 98hotrodfatboy
Yeah I'm not totally sure about the 3 5/8" cases.. I do know that S&S does make a different case for 4.0" bore and larger.. might be the way I go.. And then the pistons and cylinders..

The 4 inch / larger bore case has a 1/2 in taller deck and different cylinder stud pattern. Heads and cylinders are different.
 
Reply
Old Aug 28, 2022 | 02:19 PM
  #8  
98hotrodfatboy's Avatar
98hotrodfatboy
Thread Starter
|
Seasoned HDF Member
15 Year Member
Liked
Loved
Top Answer: 5
Joined: Mar 2010
Posts: 21,024
Likes: 7,549
From: Poolville
Default

Originally Posted by Max Headflow
The 4 inch / larger bore case has a 1/2 in taller deck and different cylinder stud pattern. Heads and cylinders are different.
I've read that even the cam chest is a half inch wider which would be necessary so yeah it's definitely a totally different design but man it sure would be nice to have 116 cubic inch motor in that baby.. My problem is I get tired with what I have and need to move forward. I guess it's like a heroin junkie.. I need another hit man.. Maybe This Time some fentanyl.. Lol..

However you might be right about maybe going to NOS or maybe even a turbo.. at this point I bet it would be cheaper than going to Cases, cylinders and Pistons.. I don't know we'll see..

But in all honesty going with those two options would create so much more power than I really want which means building a bigger drivetrain and I really didn't want to do that.. I just wanted to go with a mid grade 113-116 cubic inch 10.2:1 build that had really nice torque nothing crazy stupid.. like maybe 130-135 lb tq..
 

Last edited by 98hotrodfatboy; Aug 28, 2022 at 02:51 PM.
Reply
HD Forum Stories

The Best of Harley-Davidson for Lifelong Riders

story-0

7 Surprising Harley-Davidson Products that Are Not Motorcycles

 Verdad Gallardo
story-1

8 Best Harley-Davidson Motorcycles Ever

 Pouria Savadkouei
story-2

10 Worst Harley-Davidson Motorcycles Ever

 Pouria Savadkouei
story-3

Killer Custom's Jail Break Is The Breakout That Refused to Blend In

 Verdad Gallardo
story-4

Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?

 Verdad Gallardo
story-5

Harley-Davidson Reveals Super Cool Cafe Racer Concept

 Verdad Gallardo
story-6

Engraved Rebellion: Inside Bundnerbike's Glam Rock II

 Verdad Gallardo
story-7

10 Motorcycles You Should Never Buy

 Joe Kucinski
story-8

10 Things Harley-Davidson Needs to Fix in 2026

 Verdad Gallardo
story-9

Southpaw Super Glide: A Left-Hand-Drive 1979 Harley FXE Built to Fit the Rider

 Verdad Gallardo
Old Aug 28, 2022 | 02:20 PM
  #9  
smitty901's Avatar
smitty901
Seasoned HDF Member
Veteran: Army
15 Year Member
Liked
Community Favorite
Joined: Feb 2008
Posts: 22,998
Likes: 11,439
Default

EVO run pretty good with AC.Exhaust, head work and Cam. Followed with proper tune. If you keep it with reason they run great and darn near bullet proof.
Mine is 26 years old still doing the job.
 
Reply
Old Aug 28, 2022 | 02:40 PM
  #10  
Max Headflow's Avatar
Max Headflow
Seasoned HDF Member
Joined: Dec 2005
Posts: 19,830
Likes: 7,968
From: poway
Default

Originally Posted by 98hotrodfatboy
I've read that even the cam chest is a half inch wider which would be necessary so yeah it's definitely a totally different design but man it sure would be nice to have 116 cubic inch motor in that baby.. My problem is I get tired with what I have and need to move forward. I guess it's like a heroin junkie.. I need another hit man.. Maybe This Time some fentanyl.. Lol..

However you might be right about maybe going to NOS or maybe even a turbo.. at this point I bet it would be cheaper than going to Cases, cylinders and Pistons.. I don't know we'll see..

But in all honesty going with those two options would create so much more power than I really want which means building a bigger drivetrain and I really didn't want to do that.. I just wanted to go with a mid grade cubic inch 10.2:1 build that had really nice torque nothing crazy stupid.. like maybe 130-135 lb tq..
I don't think it's 1/2 inch but maybe about 1/8 to 1/4.. The crank would have to be different if much more. I do know that SnS TC cases have the tappet covers out about 1/8 inch. The Evo cases moved the Tappet blocks out a little.

Pic SnS EVO 88 ci base vs EVO 113 base gasket..



 
Reply



All times are GMT -5. The time now is 06:14 AM.

story-0
7 Surprising Harley-Davidson Products that Are Not Motorcycles

Slideshow: The bar-and-shield logo shows up on far more than motorcycles, some of the company's most unexpected products have nothing to do with riding.

By Verdad Gallardo | 2026-04-29 16:50:35


VIEW MORE
story-1
8 Best Harley-Davidson Motorcycles Ever

Slideshow: Not every Harley gets it right, but these are the ones that genuinely earned their reputation.

By Pouria Savadkouei | 2026-04-15 14:23:21


VIEW MORE
story-2
10 Worst Harley-Davidson Motorcycles Ever

Slideshow: From the troubled AMF years to modern misfires, these bikes earned reputations for reliability issues, questionable engineering, or disappointing performance.

By Pouria Savadkouei | 2026-04-01 20:01:09


VIEW MORE
story-3
Killer Custom's Jail Break Is The Breakout That Refused to Blend In

Slideshow: Killer Custom's "Jail Breaker" build focuses more on stance and visual aggression than mechanical overhaul.

By Verdad Gallardo | 2026-03-18 19:20:32


VIEW MORE
story-4
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?

Slideshow: The Swiss custom shop has taken a Harley Softail and stretched it into something so long and low that it looks closer to a rolling sculpture than a conventional motorcycle.

By Verdad Gallardo | 2026-03-07 16:15:30


VIEW MORE
story-5
Harley-Davidson Reveals Super Cool Cafe Racer Concept

Slideshow: Harley-Davidson's new RMCR concept revives the café racer formula with modern hardware-and it may be exactly the reset the company needs.

By Verdad Gallardo | 2026-03-04 12:23:37


VIEW MORE
story-6
Engraved Rebellion: Inside Bundnerbike's Glam Rock II

Slideshow: A standard cruiser becomes an intricate metal canvas in the hands of a Swiss custom house known for pushing Harley-Davidson platforms far beyond their factory brief.

By Verdad Gallardo | 2026-02-24 18:19:44


VIEW MORE
story-7
10 Motorcycles You Should Never Buy

Slideshow: There is no shortage of great motorcycles to buy, but we would avoid these ten.

By Joe Kucinski | 2026-02-19 14:50:51


VIEW MORE
story-8
10 Things Harley-Davidson Needs to Fix in 2026

Slideshow: Harley-Davidson's challenges aren't abstract; they show up in dropping shipments, shrinking dealer traffic, and strategic decisions that aren't yet translating into growth.

By Verdad Gallardo | 2026-01-13 18:33:17


VIEW MORE
story-9
Southpaw Super Glide: A Left-Hand-Drive 1979 Harley FXE Built to Fit the Rider

Slideshow: Graeme Billington's left-hand-drive Shovelhead is as much about problem-solving as it is about classic Harley form.

By Verdad Gallardo | 2025-12-30 11:27:08


VIEW MORE