I posted this on a machinists forum and got a bit of flame for suggesting that I might accomplish this myself with meager tooling.
I suspect we have a few more diehard diy types here so any advice would be welcomed.
The handlebar master cylinder of my '84 650 bmw is cast aluminum.
The bore is simply that. Not sleeved. It's gone through one rebuild already. Lasted a couple of years. I suspect the aluminum bore is corroded and pitted enough to make short work of a new set of seals. So I'd like to see, before I spring for 200 dollars to replace the cylinder, if I might resleeve it myself.
It's a 13mm bore presently. If I can rebore to 16mm (slightly over) I could insert and epoxy (or green Loctite)
PSM1216-12 12.05 (id) 16.04 (od) $11.09
Or similarly had dimensional linear bearing stock from online. 12mm piston/seal rebuild kits are easily and cheaply had online.
The toughest part, it would seem, is mapping and drilling the ports precisely enough.
Otherwise, I don't see the difficulty. Anyone done this? (edited)