Ordering and Installing Top Hat Liners for 4.6 Bosch Engines

StangGT5

Well-known member
Feb 4, 2019
64
16
Atlanta, GA
I have rebuilt Rover V8s, but always started with known good engines that did not overheat or make noise. However, I have good pull-outs from a P38 and a couple 04 D2s and would like to build a top hat lined engine. I would appreciate knowledgeable guidance on the following questions:
  1. Since top hat liners are supposed to be to Rover V8s what studding is to Powerstroke 6.0s, does it matter whether I start with a D2 or P38 block? I may opt to use the P38 block since they benefited from quality control methods, but if these liners are so great maybe it doesn't matter.
  2. Can the o-ringed (newer version) top hat liners be installed by any good machine shop? If not, is it worth shipping the shortblock to a machine shop familiar with Rovers (in the southeast, hopefully)? I would hate to ruin a known-good 4.6 that could just be rebuilt without new liners and run 200K if not overheated.
  3. Where is the best place to order the top hat liners and accompanying pistons (if needed)?
  4. Can you run 4.0 pistons on a 4.6 rotating assembly? I have seen some mention of this in the Australian Rover forums, and it appears to bump compression significantly. Will it still run on 93 octane without pinging in hot temps?
  5. I have always used stock camshafts, but have a 04 D2 with an aftermarket cam (bought that way, previous owner forgot brand) and it pulls noticeably better around 2250 and up. Are there any good aftermarket cams that do not sacrifice low end torque or require tuning?
 

Swedjen2

Well-known member
Sep 12, 2018
405
64
California
1. Do your blocks have any colored paint? Blue, yellow or red? The blue dot blocks are the best of the 3 as far as dimensional accuracy and eveness between bore diameters.
2. I wouldn't give the job to any machine shop. They would be learning on the job. I'd ship it. Someone around here must know of a good shop near you. If not you could ship it to D&D in Michigan. They've been doing work on aluminum V8's since the 70's, maybe earlier.
D&D Fabrications, Inc.
Attention: Dan Lagrou, President
Mark Lagrou, C.C.B.W.
8005 Tiffany Drive
Almont, MI 48003 USA
Phone: 810-798-2491 9:00 A.M. - 5:00 P.M. M/S EST
Fax: 810-798-2777 Anytime​

3. D&D has the liners and can machine and install.
4. Ask them.
5. I have a Wedge shop cam. I think it's more of a street cam and not an off-road, low torque cam. If I put it in Sport mode, it does get out of it's own way pretty well, but I would say its similar to yours - comes on around 2000-2500 rpm's.
I would try a Crower - quite a few here run them. I believe Turner Engineering out of the U.K. sells Kent Cams. They have an excellent reputation.

H180 Kent Sports Torque Rover V8 camshaft


Kent Cams H180 'Sports Torque' camshaft has been designed as a straight forward replacement performance cam for the Rover V8 engine.

With a duration of 262º and a valve lift of 11.2mm the H180 camshaft improves low end torque and is capable of increasing peak power by 22bhp, all whilst retaining the use of OE valve springs and maintains stable idle characteristics essential for: everyday use, on or off road, manual or automatic gearbox cars.

An improved version of the former Kent sports torque H180 v8 camshaft

The new camshaft is produced on an improved 'Chilled Iron' cam blank which gives significantly superior reliability over the original production cams.

We recommend replacing the hydraulic cam followers when changing a camshaft and using Competition Cam Shaft Lube
 
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Maximumwarp

Well-known member
Mar 22, 2015
804
12
Fairburn GA
There’s a machine shop out in Winder called Eagle Machine. They specialize in British stuff. I’ve had them do a cpl sets of D2 heads, and they came out beautifully, but of course liners are a bit more involved. Call them and see if they’ve done it before, good chance they have.
 
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Lake_Bueller

Well-known member
Aug 11, 2004
1,989
36
52
Beloit, WI
  1. Where is the best place to order the top hat liners and accompanying pistons (if needed)?
I actually have everything you need already in a box from Turner Engineering out of the UK. I bought it with the intention of having a block done with the flanged liners. At the end of the day, I found a totaled D2 with a freshly rebuilt engine. The parts are listed in the classified section. Search "Turner"
 
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StangGT5

Well-known member
Feb 4, 2019
64
16
Atlanta, GA
Guys, thank you so much for the all the response. This is very helpful. I have a bit of time before I move forward, but your responses have provided a great roadmap. I will contact the machine shops noted above.

Swedjen2, I have not checked the block colors yet but good idea. I think one of us has recieved the color designations backwards though. The rover engine guide I have says the red blocks are the best, and blues were the worst. Based on that, P38s should have red blocks and my 04 D2 engines could be red or yellow (hopefully not blue).
 
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wrldky

Well-known member
Apr 21, 2004
377
2
Raleigh, NC
Had my 4.0 resleeved right here in Raleigh, NC from a Machine Shop that does a lot of them for a local Rover Garage. Had the engine rebuilt and the sleeves installed for $1850. The sleeves I bought from Turner Engineering for 474 Pounds. Pistons were 220 pounds from Rimmer Brothers.
 
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