#nikasil

When it comes to rebuilding an aircooled Porsche 911 engine, choosing the right porsche cylinders is one of the most important decisions an engine builder can make. The cylinder material, bore finish, piston compatibility, and ring package all play a major role in performance, oil control, heat transfer, and long-term durability.

For many classic Porsche 911 applications, OEM Mahle cast aluminum Nikasil-plated cylinders remain the benchmark. Mahle has been an original equipment supplier to Porsche since Porsche’s beginning, and their aircooled 911 cylinders are produced and machined to original equipment tolerances for performance, durability, and longevity.

View replacement Mahle OEM Porsche cylinders from LN Engineering

What Is Nikasil?

Nikasil is a nickel-silicon carbide cylinder bore plating used on aluminum cylinders. The aluminum cylinder provides excellent heat transfer and reduced weight, while the hard nickel-silicon carbide bore surface gives the piston rings a durable, low-friction surface to run against.

Porsche was an early adopter of Nikasil technology, using it in high-performance and production aircooled engines because it allowed aluminum cylinders to shed heat efficiently while still providing a long-lasting wear surface. For aircooled Porsche engines, where temperature control and cylinder stability are critical, that combination is especially valuable.

Available OEM Mahle Nikasil Porsche Cylinders

LN Engineering lists single replacement OEM Mahle cast aluminum Nikasil-plated cylinders for Porsche 911 engines in several bore sizes. These are useful when replacing damaged cylinders, rebuilding original engines, or matching an existing Mahle cylinder set.

PC80-001 — 80 mm Mahle OEM Porsche 911 cylinder for 2.0L engines, 1964–1968. Also fits Porsche 914-6 2.0 applications.

PC84-001 — 84 mm Mahle OEM Porsche 911 cylinder for 2.2L engines, 1969–1971, and 2.4L engines, 1972–1973.

PC86-002 — 86.7 mm Mahle Motorsport cylinder associated with 911S 2.5L long-stroke applications. LN Engineering also notes that replacement OEM Mahle cast aluminum Nikasil cylinders are available in 86.7 mm.

PC98-001 — 98 mm Mahle OEM Porsche 911 cylinder for 3.0L, 3.2L, and 3.3L engines, 1978–1992.

PC102-001 — 102 mm Mahle OEM Porsche 911 machine-in cylinder with 109 mm case register for 3.6L and 3.8L applications, 1989–1998.

PC102-002 — 102 mm Mahle OEM Porsche 911 slip-fit cylinder with 107 mm case register for 3.6L applications, 1989–1998.

Slip-In vs. Machine-In Porsche Cylinders

Some Mahle Motorsport porsche cylinders are available in slip-in or machine-in configurations. Slip-in cylinders are designed as larger internal bore replacements that fit the existing case register. Machine-in cylinders require machining the engine case for a larger spigot diameter.

For more extreme applications, including highly boosted turbo engines or competition builds, the larger spigot diameter of a machine-in cylinder can be preferable because it provides additional strength and support.

Why Replace Cylinders as a Complete Set?

LN Engineering recommends replacing Porsche cylinders as a complete set whenever possible. If a single cylinder is replaced, the engine builder is responsible for matching cylinder height groups, which may require modification of one or more cylinders.

This is especially important on aircooled Porsche engines, where deck height, compression ratio, cylinder sealing, and cylinder-to-cylinder consistency all matter.

When OEM Mahle Cylinders Are No Longer Available

For some aircooled Porsche 911 applications, original-style OEM Mahle cylinders are no longer available. In those cases, Mahle Motorsport has partnered with LN Engineering to offer piston and cylinder sets using LN Engineering’s billet aluminum Nickies cylinders.

Nickies cylinders also use a nickel-silicon carbide bore surface and are designed as a modern replacement or upgrade where original Mahle Nikasil cylinders are unavailable or where additional strength, cooling, and performance are desired.

The Bottom Line

For anyone rebuilding an aircooled 911 engine, the right porsche cylinders are not just replacement parts. They are a major part of the engine’s durability, oil control, heat management, and performance.

OEM Mahle Nikasil cylinders remain one of the most respected choices for classic Porsche 911 engines, and LN Engineering offers replacement Mahle cylinders along with Nickies-based alternatives for applications where new OEM Mahle cylinders are no longer available.

Understanding Nikasil Cylinder Plating: The Gold Standard in Engine Performance and Longevity

When it comes to high-performance engines, Nikasil cylinder plating is a game-changer. Known for its durability, heat resistance, and ability to improve engine efficiency, Nikasil has become a cornerstone in advanced engine technologies. In this blog, we’ll dive into what Nikasil is, why it’s superior, and how it compares to NSC (Nickel Silicon Carbide) plating.

What is Nikasil?

Nikasil, short for Nickel Silicon Carbide, is a proprietary cylinder plating process developed in the late 1960s. It involves coating engine cylinder walls with a thin layer of nickel infused with silicon carbide particles. This coating is applied via an electroplating process, creating an exceptionally hard and wear-resistant surface.

Originally developed for high-performance racing applications, Nikasil has since been adopted for use in motorcycles, aircraft, and high-performance automotive engines, including Porsche engines. Its combination of strength, thermal conductivity, and lightweight properties makes it ideal for aluminum engine blocks.

Benefits of Nikasil Cylinder Plating

Superior Wear Resistance The silicon carbide particles in Nikasil create an incredibly hard surface that can withstand the friction and stress of high-performance engines, reducing wear on piston rings and cylinder walls.

Improved Heat Dissipation Aluminum blocks with Nikasil plating are better at dissipating heat compared to cast iron sleeves. This helps maintain consistent operating temperatures and prevents overheating.

Lightweight Design By eliminating the need for heavy cast iron sleeves, Nikasil allows for the use of lightweight aluminum blocks, reducing the overall weight of the engine.

Corrosion Resistance Nikasil's nickel layer provides excellent protection against corrosion, even when exposed to ethanol-blended fuels.

Enhanced Engine Efficiency The smooth, hard surface created by Nikasil reduces friction, improving engine efficiency and performance.

Nikasil vs. NSC (Nickel Silicon Carbide)

While Nikasil and NSC are often used interchangeably, NSC is an evolution of the original Nikasil process. Both involve Nickel Silicon Carbide coatings, but modern NSC processes are refined to improve consistency and performance further. These advancements ensure better adhesion and even greater durability, making NSC a preferred choice for modern engines.

Key Differences:

Application Improvements: NSC utilizes updated electroplating techniques for better precision and uniformity.

Environmental Considerations: Modern NSC processes are designed to be more environmentally friendly, addressing concerns associated with older Nikasil plating techniques.

Performance Edge: NSC offers marginally better thermal and wear properties, making it ideal for the most demanding applications.

Nikasil and Porsche Engines

Porsche has been a pioneer in adopting Nikasil and NSC cylinder technologies. High-performance models, including the iconic 911, have utilized Nikasil to achieve unmatched reliability and performance. Engines equipped with Nikasil cylinder liners are known for their longevity and ability to withstand extreme conditions, making them a favorite among enthusiasts and professionals alike.

LN Engineering offers its billet aluminum NSC plated aluminum Porsche cylinders for Porsche engines, whose benefits include:

Greater Surface Area and Thermal Conductivity

Nickies have more surface area and up to twice the thermal conductivity of factory Mahle cast aluminum cylinders.

Nickies have as much as four times the thermal conductivity of cast iron or ductile iron cylinders.

Superior Strength and Durability

Nickies have up to 50% greater tensile and ultimate yield strength than OEM Porsche cast aluminum cylinders.

Nickies are stronger and more ductile than any cast iron, ductile iron, or aluminum OEM or aftermarket cylinders.

Expanded Sizing Options

Nickies allow for larger slip-fit and machine-in sizes than previously available with cast iron or aluminum cylinders.

Improved Performance Features

Most Nickies cylinders for Porsche applications come half-mooned for improved crankcase windage, providing a performance boost of approximately 8-10hp over factory Mahle non-half-mooned cylinders.

Compliance and Manufacturing Excellence

Nickies are SCCA legal.

Nickies are 100% made in the USA.

Maintaining Nikasil-Plated Cylinders

To maximize the lifespan and performance of Nikasil cylinders:

Use High-Quality Oils: Always use oils formulated for high-performance engines to ensure proper lubrication and prevent premature wear.

Regular Maintenance: Keep your engine in top condition by following recommended service intervals.

Avoid Abrasive Cleaners: When cleaning Nikasil-plated cylinders, avoid using abrasives that could damage the plating.

Conclusion