Generation III Internal Engine 1997-2006 LS1 | LS6
Sponsored by:
Sponsored by:

Fly Cutting stock pistons

Thread Tools
 
Search this Thread
 
Old Dec 17, 2003 | 09:21 AM
  #1  
Crazy C5 Cowboy's Avatar
Thread Starter
Teching In
 
Joined: Nov 2003
Posts: 33
Likes: 0
Default Fly Cutting stock pistons

Anyone know what the most you can safely cut a stock piston is? Drilled an old stock and you've got about 8mm of metal where the cutting is being done.... anyone who KNOWS for sure let me know! Please no guesses.... PLEASE
Reply
Old Dec 17, 2003 | 10:21 AM
  #2  
GenXreject's Avatar
Teching In
 
Joined: Nov 2003
Posts: 19
Likes: 0
From: Winterpeg, Manisnowba, Canada
Default

I dont have an answer for you, sry. But I do have a question for you. What would be the benefit of cutting stock pistons? To save weight? How badly would this effect durability?
Reply
Old Dec 17, 2003 | 10:38 AM
  #3  
2002WS6_MN6's Avatar
Launching!
20 Year Member
 
Joined: Nov 2002
Posts: 261
Likes: 0
From: Freehold, NJ
Default

I recall reading something about not cutting stock pistons due to the high location of the compression ring land. I may have read it in the LS1 performance book.. Maybe..

Eventhough you have 8mm thickness you need to measure the thickness between the top of the piston and the first ring land groove..

I'd also like to know why you would cut a stock piston? Why wouldn't you just put in a set of new pistons if going through all that work?
If you're looking to lower your compression you could use a different head gasket.. Is this gonna be a FI car?
Reply
Old Dec 17, 2003 | 12:08 PM
  #4  
Slowhawk's Avatar
LS1Tech Sponsor
iTrader: (12)
 
Joined: Nov 2001
Posts: 14,865
Likes: 6
From: Bridgewater,Ma
Default

You can cut .080 safely. .060 if nitrous is to be used.
Reply
Old Dec 17, 2003 | 01:55 PM
  #5  
robertbartsch's Avatar
TECH Veteran
 
Joined: Aug 2002
Posts: 4,055
Likes: 1
From: Hartsdale, NY
Default

...flycutting pistons is used to allow use of a bigger cam.... ...it can be done with the shortblock in the car...

Suggestion: Rent the special head that has the valve seats removed...
Reply
Old Dec 17, 2003 | 03:04 PM
  #6  
SPANKY LS1's Avatar
TECH Junkie
20 Year Member
iTrader: (24)
 
Joined: Nov 2001
Posts: 3,490
Likes: 1
From: Seneca, SC
Default

Lou at LG told me he has seen pistons cut .100 successfully , but, as Slowhawk said, .080 is the generally accepted maximum.

The reason to flycut factory pistons -vs- installing aftermarket pistons is ease and cost. It can be done with the shortblock in the car, and if done correctly and the correct amount, should not affect the piston's strength or longevity (unless large nitrous or boost is being used, in which case even a stock, unmodified piston would most likely fail). Also, is cheaper than installing new pistons, balancing, machine work, labor, etc. My pistons will be flycut about .070, fwiw (AS Stg 2.75, G5X3 on 112).

Shawn
Reply
Old Dec 17, 2003 | 05:44 PM
  #7  
2001CamaroGuy's Avatar
TECH Veteran
iTrader: (6)
 
Joined: Feb 2002
Posts: 4,766
Likes: 0
From: Phoenix, AZ USA
Default

~0.070" (+/- 0.010") seems to be a general consists on how much you can fly cut stock pistons.
Reply
Old Dec 17, 2003 | 07:51 PM
  #8  
Crazy C5 Cowboy's Avatar
Thread Starter
Teching In
 
Joined: Nov 2003
Posts: 33
Likes: 0
Default

Thanks for the info guys! I talked to a couple performance shops that are supporting vendors here and on the Corvette Forum and they all told me for my setup I would need a minimum .080, up to .10 - pretty much what you all have said. Thanks again! Happy Holidays
Dan
Reply
LS1 Tech Stories

The Best V8 Stories One Small Block at Time

story-0

6 Common C5 Corvette Failures and What's Involved In Repairing Them

 Pouria Savadkouei
story-1

Retro Modern Bandit Pontiac Trans AM Comes With Burt Reynolds' Autograph

 Verdad Gallardo
story-2

Top 10 Greatest Cadillac V Series Performance Models Ever, Ranked

 Pouria Savadkouei
story-3

Top 10 Most Powerful Chevy Trucks Ever Made!

 
story-4

Hennessey's New Supercharged Silverado ZR2 Has 700 HP

 Verdad Gallardo
story-5

Coachbuilt N2A Anteros Is an LS2-Powered C6 Corvette In Italian Clothes

 Verdad Gallardo
story-6

Awesome K5 Blazer Restomod Comes With C7 Corvette Power

 Verdad Gallardo
story-7

10 Camaros You Should Never Buy

 
story-8

10 LS Engine Myths That Refuse to Die

 Verdad Gallardo
story-9

Five Reasons the Camaro Was the Most Pivotal Player in the Pony Car Wars 2.0

 Brett Foote
Old Dec 17, 2003 | 08:03 PM
  #9  
2001CamaroGuy's Avatar
TECH Veteran
iTrader: (6)
 
Joined: Feb 2002
Posts: 4,766
Likes: 0
From: Phoenix, AZ USA
Default

spanky, what size valves do you have? Any idea how many CCs you will be adding with the fly cuts?
Reply
Old Dec 17, 2003 | 08:07 PM
  #10  
SPANKY LS1's Avatar
TECH Junkie
20 Year Member
iTrader: (24)
 
Joined: Nov 2001
Posts: 3,490
Likes: 1
From: Seneca, SC
Default

My heads have a 2.04 (custom) intake valve, I am not sure on the CC of the valve relief....I may lose .1 of compression, but my heads were prepped/milled with this in mind, and my gaskets are .041 compressed (versus .060 stock), so, I should be good to go.....

Shawn
Reply
Old Dec 17, 2003 | 08:24 PM
  #11  
Bink's Avatar
TECH Addict
20 Year Member
 
Joined: Jul 2002
Posts: 2,261
Likes: 0
Default

Originally Posted by Crazy C5 Cowboy
Anyone know what the most you can safely cut a stock piston is? Drilled an old stock and you've got about 8mm of metal where the cutting is being done.... anyone who KNOWS for sure let me know! Please no guesses.... PLEASE
Ed Potter @ Lingenfelter told me 0.100" Notch is OK with stock hypereutectic pistons. FWIW.
joel
Reply
Old Dec 17, 2003 | 10:03 PM
  #12  
Whistler's Avatar
Sawzall and Welder Mod
20 Year Member
Photogenic
Photoriffic
Shutterbug
iTrader: (46)
 
Joined: Nov 2001
Posts: 2,486
Likes: 4
From: Orlando, FL
Default

He got a killer deal on a set of JPR's heads that were milled .060, and is trying to run a cam with almost .600 lift and 230 degrees of duration.

We did a preliminary cut of around .065/ .035 into the pistons, clayed, and still had too close a fit. Looks like the reliefs are going to end up being around .125 on the intakes, It'll probably be fine.
Reply




All times are GMT -5. The time now is 06:16 PM.

story-0
6 Common C5 Corvette Failures and What's Involved In Repairing Them

Slideshow: From wobbling harmonic balancers to failed EBCMs, these are the issues that define long-term C5 ownership and what repairs typically involve.

By Pouria Savadkouei | 2026-05-07 18:44:57


VIEW MORE
story-1
Retro Modern Bandit Pontiac Trans AM Comes With Burt Reynolds' Autograph

Slideshow: A modern Camaro transformed into a retro icon, this limited-run "Bandit" build blends nostalgia with brute force in a way few revivals manage.

By Verdad Gallardo | 2026-04-21 13:57:02


VIEW MORE
story-2
Top 10 Greatest Cadillac V Series Performance Models Ever, Ranked

Slideshow: Cadillac didn't just crash the high-performance luxury vehicle party, it showed up loud, supercharged, and occasionally a little unhinged...

By Pouria Savadkouei | 2026-04-16 10:05:15


VIEW MORE
story-3
Top 10 Most Powerful Chevy Trucks Ever Made!

Slideshow: Top ten most powerful Chevy trucks ever made

By | 2026-03-25 09:22:26


VIEW MORE
story-4
Hennessey's New Supercharged Silverado ZR2 Has 700 HP

Slideshow: Hennessey has turned the Silverado ZR2 into a 700-hp off-road monster with supercharged V8 power and a limited production run.

By Verdad Gallardo | 2026-03-24 18:57:52


VIEW MORE
story-5
Coachbuilt N2A Anteros Is an LS2-Powered C6 Corvette In Italian Clothes

Slideshow: A one-off sports car that looks like a vintage Italian exotic-but hides a C6 Corvette underneath-just sold for the price of a new mid-engine Corvette.

By Verdad Gallardo | 2026-03-23 18:53:41


VIEW MORE
story-6
Awesome K5 Blazer Restomod Comes With C7 Corvette Power

Slideshow: A heavily reworked 1972 K5 Blazer swaps its off-road roots for a low-slung street-focused build with modern V8 power.

By Verdad Gallardo | 2026-03-09 18:08:45


VIEW MORE
story-7
10 Camaros You Should Never Buy

Slideshow: There are thousands of used Camaros on the market but we think you should avoid these 10

By | 2026-02-17 17:09:30


VIEW MORE
story-8
10 LS Engine Myths That Refuse to Die

Slideshows: Which one of these myths do you believe?

By Verdad Gallardo | 2026-01-28 18:10:11


VIEW MORE
story-9
Five Reasons the Camaro Was the Most Pivotal Player in the Pony Car Wars 2.0

The world was a better place when it was still around.

By Brett Foote | 2026-01-23 09:20:37


VIEW MORE