Serious 500HP Engine Rebuild!! Need your help !, After the first engine rebuild went totally wrong Options

[snakeloa]

Hello Mates,

i need your help. And i need it desperatly!

My old engine rebuild went totally wrong. I will shortly tell you (the original Topic can be found here):
After a small scratch found in one of my cylinder walls we decided to rebuild the engine. As the scratch was to big to bore it out slightly and use oversize pistonrings we decided to bore it out bigger and sleeve the block with Chrome Molly Ductile Sleeves and fit slightly oversized CP Pistons 86,5mm with outer polymer friction coating and ceramic top coating in it. We decided to sleeve as the goals were to high to believe that the thinn walls could keep up with it.

Well to make it short the messed up the sleeves and the block (and the cams and and ..). We decided to buy new sleeves and to let them try again (it is our law who tells us to give a 2.nd chance) They sleeved it again and i hoped they did a good job. As was sure about it i sent the whole engine to the US to enginelogics (he fully ported the cylinderhead). He called in yesterday....

"Yes bad news he said. We opened the crate today and unfortunately I do have to give you bad news. Who ever did the sleeving work did a very poor job of it. I am sure you noticed that the some areas of flange part of the sleeve does not even touch the side of the block. This is total unacceptable and it is my opinion that if I were to use that block the engine will not last very long."

The next problem is that we seem not to be able to get a 3rd set of sleeves as he would have to order 10 sets and pay them in advance. That is to much to ask him.

OK now its time for a really serious engine rebuild!
And i need your Help

My goals were and are:
500bhp of an engine that can rev up to 8500
the focus was on good torque troughout the whole rev range.
The car should be for the nice mountain roads here in the black forest. A pure fun car for sportive driving.
I do not go onto the track often and do not need a lot of 1/4 miles to face.
My old Spec sheet can found in my signature!

Well the question is now were to start over again. Please keep the goals in mind and i only have one more try. I allready spent a fortune.

All parts are fine except the block and the sleeves. They are to unstable for my kind of goals.

What new block would be good to use?
Does it have to be sleeved?

cheers Joerg
And i hope you can help.

This post has been edited by snakeloa: Sep 6, 2008 - 3:24 PM