I don't think you can have the sleeve too tight in the bore. The sleeved
master cylinders I've had leaked between the bore and the sleeve. Others I
know have complained of air apparently being trapped between behind the Sleeve.
I would expect you'd want to chill the sleeve and heat the cylinder to help
ensure a tight fit.
At least two of the sleeved master cylinders I've owned had the holes drilled
in the insert prior to assembly. One unit did not have the holes line up and a
second set was drilled after insertion. Another has holes that do not
perfectly align. I do not see any particular reason you could not drill the
holes after insertion though.
Distortion of the brass insert was visible on some of my sleeved master
cylinders. One of them it was so severe as to result in binding of the piston
in its travel.
There does seem to be a relationship between problems and what is sleeved.
Specifically, sleeved master cylinders seem far more trouble prone then sleeved
slave cylinders. Just something I've noticed in conversations with shops and
my own experience. I do not know why this seems to be.
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