Cylinder Liner Removal Mandrel – Jaguar V12

Create a precision-machinable cylindrical removal puck/mandrel for pushing a cylinder liner upward out of a Jaguar XKE Series 3 5.3L V12 aluminum engine block. Units: inches. The tool consists of two coaxial cylindrical sections machined from one solid piece. LOWER / PILOT SECTION: * Diameter: 3.538 inches * Length: 1.000 inch * This section enters inside the cylinder liner. * The liner internal diameter is approximately 3.543–3.544 inches, so the pilot must slide freely inside it without binding. * Add a small 0.030-inch × 45-degree chamfer around the leading edge to facilitate insertion. UPPER / SHOULDER SECTION: * Diameter: 3.845 inches * Thickness: 0.500 inch * This creates an annular shoulder that contacts the bottom edge of the cast-iron cylinder liner. * The cylinder liner external diameter is approximately 3.858–3.859 inches. * The shoulder must push ONLY against the liner and must not contact the surrounding aluminum engine block. * Add a small 0.020-inch edge break/chamfer to external sharp edges. CENTER: * Add a centered through-hole, 0.656 inch diameter, through the entire tool. * The hole is clearance for a 5/8-inch threaded rod. * Do NOT add threads. CLEARANCE FLATS: * Add two identical parallel flats on opposite sides of the 3.845-inch shoulder. * Flats must be symmetrical around the center axis. * Machine each flat sufficiently to reduce the overall width across the flats to 3.500 inches. * The flats are required to clear adjacent structures inside the Jaguar V12 crankcase. * Flats apply only where required on the large shoulder; preserve the circular 3.538-inch pilot section. OVERALL: * Total axial length: 1.500 inches. * Pilot and shoulder must be perfectly concentric. * The transition between the 3.538-inch pilot and 3.845-inch shoulder must form a flat 90-degree annular load-bearing face. * Do NOT fillet this load-bearing shoulder. * Keep the design simple and suitable for CNC turning followed by a simple milling operation for the two flats and drilling the central hole. Material specification for manufacturing: 6061-T6 aluminum. The finished part is a cylinder-liner removal mandrel. It is inserted from underneath the engine block, with the pilot entering the cylinder bore and the shoulder contacting the lower end of the liner. Axial force applied through the tool pushes the cast-iron liner upward out of the aluminum engine block. Generate a dimensionally accurate solid CAD model suitable for export as STEP/STP.

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