It should be do-able. It may depend on the quality of the aluminum alloy
in the head. Similar things are done in the aircraft industry.

On piston type aircraft engines, the cylinders are made as individual
units, complete with cylinder head. The heads are not separate as on the
WBX engines. The principle is the same -- steel cylinder barrel,
aluminum head - but on the WBX he heads are separate.  On this type
cylinder, an aluminum head is screwed onto a steel barrel in such a way,
and under such conditions, that the head and barrel are a permanent
assembly. The aluminum head has valve rocker bosses machined into the
aluminum head on top. There are four, and they are aligned two by two so
as to accept individual rocker shafts.  Cylinders  used by the US
military are often surplused out, in a used but serviceable condition.
When they are released, the rocker bosses for the rocker shafts are
deliberately broken off, usually just struck with a hammer. When the
broken cylinders are delivered by a surplus purchaser to a certified
engine repair facility, the shop will weld back in new material where
the bosses are broken, then align and drill out the new boss material.
Upon completion of the rest of the cylinder repair, the cylinder is
inspected, then re-certified as airworthy.

The point in all this is....there is no reason that welding in new
materials and re-machining cannot be accomplished. Might be pricey, however.

Regards,

John Rodgers
88 GL Driver

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