Have a "01 24v that is going into a 2005 F-250. Engine is completely stripped and ready to head for the machine shop. I'm going to have the block and head milled back to flat and the #3 cyl looks like someone took a spoon and took a chunk out of it. My guess is that at one point there was a peice of an injector rattling around in there. We have a really great machine shop here who is going to bore and sleeve it back to 5.9. Being relativly new to the Cummins world is there anything out there that anyone can think of that I should look out for? I'm also curious that if I end up with a bigger bore than the original 5.9 if I will have to adjust any stroke? Tryiing to keep this build on a budget so I want to avoid any monsters in the closet.

 

you can bore to whatever you want with no issues, but decking the block you will have to have the pistons milled down most likely. the piston already petrudes from the block and if you mill the block you may hit the head with the pistion. you will have to check piston petrusion.

 

A different option to milling the pistons is a thicker head gasket. Depending on how much you take off, a thicker head gasket is much cheaper and quicker.

 

true your are correct but in my case extreme boost on a thicker gasket just means easier to blow out. plus with mine its fire ringed and to my knowledge as well as most of the suppliers i deal with there is not a thicker ringed gasket.