Sleeve Removal Puck Sizes

[equeen]

I have an opportunity to have a few sleeve removal pucks made at a very reasonable price. I'd appreciate help regarding dimensions.

It appears that the block bore and sleeve OD at the seal for two engines I'm working with at the moment is 3 7/16 (3.4375).

Question 1: What should be the "outer" diameter of the puck?

Question 2: What should be the "inner" diameter of the puck for:

3 1/4 bore sleeves?

3 1/8 bore sleeves?

3.1875 bore sleeves?

Question 3: How thick should the "steel" puck be from the bottom of the puck to the cut for the "inner diameter" of the puck?

Thanks.
 

[El Toro]

You may also need the measure the block so the outside diameter of your pucks will clear the block. If the bore diameter on the sleeve is 3.00" at the seal under cut the puck to 2.990" to 2.987". On the 3.125" bore undercut puck to 3.115" to 3.113" and on the 3.1875 bore undercut to 3.1865-3.1863". Since these sleeves are probably worn, a .010" undercut on the puck should fit easily into the bore of your worn sleeve. Hal
 

[equeen]

Thanks, El Toro.

Man is that 3.25 bore a thin-walled sleeve!
 

[Nebraska Kirk]

I have made several of those pucks for pulling sleeves, I always make the inside diameter .010" smaller than the sleeve bore. As far as the outside of the puck is concerned, is all depends on the outside diameter of the sleeve. Different diameters of sleeves have different wall thicknesses, as well as dry versus wet sleeves, there is no standard that says X + sleeve bore = outside diameter.

I usually make the step from smaller to larger diameters 3/16" to 1/4" wide.
 

[equeen]

Thanks, Kirk.

I understand the different wall thickness. However, it would seem that the block bore, unless tinkered with, would be the same for 3 1/8 to 3 1/4 sleeves.

Looking at a sleeve and piston kit for 3 1/4 overbore - stepped piston - 3.436 Lower Sleeve Diameter. One of my blocks currently has 3 1/4 pistons. Thus I'm "assuming" that lower sleeve diameter is ~ 3.436. If I'm assuming correctly, what should be the largest diameter of the puck to pull the sleeve and clear the block?
 

[Nebraska Kirk]

Make the larger diameter of the puck at least .010 smaller than the outside diameter of the bottom of the sleeve. On the thicker walled wet sleeves you can go a little smaller yet, say .020