On Sat, 29 Jul 2006 09:20:49 -0700, Keith Hughes
wrote:

That is why I am here, to get information on how to properly engineer
it. I am an engineer so with proper input I think this can be done.

Well then, surely you must know that you first need the designed
combustion chamber temperature range and the thermal conduction profile
for the cylinder sleeve (top to bottom), to properly size the multiple,
vertically segmented, cooling loops you'll require. You could estimate
the vertical temperature cline by analyzing the relative fin surface
areas, air flow rates, and standard thermal conduction value (F sub r, U
sub L as ASHRAE defines it) and the emissivity of the fin material. And
that just gets you the info you need to design the heat exchange
process. You need to go through the same exercise with the copper
tubing with the bonding method, heat transfer characteristics, mass flow
requirements, baffling to ensure turbulent flow, etc., etc. Not a
trivial exercise.

You could always just measure the temp of the head and block in
different locations and under different loads. Knowing the difference
in block temp at idle and full load would be very useful.

Using a thermocouple(s) to measure the block temp between the fins
would be a good start. It may be the fins are designed to give a
fairly even temp throughout the block itself.

Some slightly oversized copper tube that's squashed to give an
interference fit between the fins should give good conduction, if not
enough then use more than one layer.

In testing the thermocouple could be used to monitor the block temp
under water cooling, to ensure it's within the same values as for air
cooling.

One issue with copper is that it may fracture through vibration if not
supported properly, so stainless may be better for some parts.

A tank, manifold, thermostat, pressure relief, and raw water heat
exchanger would also be needed. Also a thermal cutout if the cooling
fails. Different temps at top and bottom of block could be accomodated
by different thermostats.

Doing some practice on an old engine might give some useful lessons.

cheers,
Pete.