I hear people saying that the vitara pistons sit real loose in the stock bore so I was thinking what if you bought some low friction spray on coating and tried to build up the skirts some to tighten up the clearance. I got this idea from reading t.o.o.'s 2.0 build write up. I don't know if you could get the stuff cheap enough to make it worth it (still end up way cheaper than forged $400+). I might try it, but I wonder if buying used forged pistons is smarter.

 

i cant think of anything you could use other than chrome. in airplanes they chrome the cylinders if they are already bored out to their max, but seating rings with chrome cylinders is kinda hit and miss.

 

This is one those times where you probably should spend money to get the job done right.
And no, ---- lube wont work on your cylinder walls.

 

Dont be a cheap ***, opt for the srps ------

 

http://www.techlinecoatings.com/Engine.htm

I used DFL-1 on the skirts of my std bore vitaras. It still slapped a bit upon startup in a dingleberry honed a6 with 10w30. I also used CBC1 on the tops. I've only driven the car about 30 miles n/a. I plan on putting some 20w50 in it and boosting it this spring. I'll let ya'll know how it goes.

One thing that techline says about DFL-1 though, "Requires no clearance changes to compensate for the coating." So if I had it to do over I'd use the oversize vitaras with coatings and bore the cylinder to a stock piston to wall clearance.

 

used techline coating system before on a v-8 and it was awesome and easy but baking this stuff be prepared for the unusual smell these coating make. But this stuff is awesome worth the money I did this about 6 years ago I got the starter kit from summit racing for about $40 bucks.