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Hi Dom, the V8 will be awesome. Your penance is that you now MUST make a V twin motorcycle from the cut out section. Good luck!

This was a lovely bit of CAD. Cardboard Aided Design.

Cutting mid cylinder is how Allen Millyard does his engines then makes a solid mandrel to locate the main beatings to true it up when welding together again so it seems you have a good plan.

Mr Millyard uses a hacksaw and gets everything together after by lining up on a mandrel so don't worry. Get chopping 😊

I must be honest, I had a lot of trepidation about your intent to cut this down. However, after seeing this video (and the truly BEAUTIFUL job you did with the 2 smaller repairs) I have no doubt this will indeed be a success. Well done Dom!

Hi Dom, I would CNC cut two plates with the stud pattern to bolt on the top of the block to keep it in line for welding! For good measure have a word with the king of engine block cutting Alan Millard!.

Hi Dom, I’ve just been watching MR Hewes on YouTube ( he restores tanks) he just picked up Gulf war centurian . I spotted a V12 liberty engine on there ! Mostly complete ..worth a look 👍🏼
Keep making the videos . Always a good watch

I used to weld and repair VW engine cases, reinforced racing cases and did a couple 1/2 VW aeros and found that cutting up scrapped cases and making my own filler material from those made a ton of difference in the quality of the repairs IE: parent metal filler material. I would get the cases hot in my tank using a non caustic soap and letting them hot soak for a day or so leached as much of the oils and grease out as humanly possible. Might be a good idea to find someone to setup one or both case halves in a mill to get them to perfect final dimensions minus a few thousands and then veeing out the mating surfaces for good weld penetration would make for best result. I developed a technique where I would strike an arc and heat a puddle, that would tend to "float" impurities to the surface, then grinding the impure surface and then made the final pass(s) almost perfect. You can use the spare crank shaft to make your most important mandrel out of and a flat plate or even a couple spare cylinders for increased support and accuracy. Maybe even do the sump first and bolt that on for extra rigidity? Then just need to find a good crankshaft machinist. Even tho I retired from custom fab a few years back your project makes me itch to do something like what you are doing; just wish the Liberty Aero engine parts were not so rare. Hmm, I just realized you are going to have the spare engine and parts left over.. Enough to make a V-2 or V-4. Hmm. I know it looks a little daunting at first glance but I really think it won't be as difficult as it appears. Keep up the good work and keep posting videos of the process so us old guys can live vicariously thru you, LoL.

After you finish welding the block you can make a cast and pour a new one to have a spare.

I wouldn't dare to try and cut an aluminium engine in half with a view to welding it back together but two cuts - removing a whole cylinder with half a cylinder either side gives me the shivers!  Dom, I'm hooked, I can't wait to see the engine put back together then run up, then raced!  You are a real master craftsman, I wish you success.  I'll be looking over your shoulder every step of the way, living vicariously through your skilful spanner wielding.  Get stuck in matey, I'll be right behind you.

Can't wait to see it run, I bet it will sound epic 👍

Getting some popcorn ready for the comments section 🍿

Wow....absolutely incredible stuff; that first cut must've been terrifying!

Don't fret about cutting it up, there's plenty of liberty's still in existence.
Talk to me if you need info on having the crank made, I spent 7 years machining bespoke billet crankshafts.
Love what you're doing. 👍

Excellent progress Dom and your welding looks great

Well done Dom, you are a wild man❤

Fortune favours the brave!! I love the fact you’ve just whacked the engine in half,just because you want to. We need more madness like this in the world. Looking forward to it progressing and seeing 8 open headers spitting flames and fury.

Excellent episode. Thank you Dom.

I wouldn't worry about using an angle grinder. Dom ,Alan Millyard uses a hacksaw.