I've been aware for many years that there were differences between the cylinder liners for the two brands of engine, but until now never had to deal with the issue and didn't know exactly what the differences were.
I'm posting this in case it's helpful to someone else contemplating fitting new liners into their National.
Here's a National liner alongside a new RN liner:-
Actually the difference visible in the pic isn't what matters. Old RNs had the same sealing system at the bottom, a gland screwed up from below which compressed a rubber ring The new liners use the more conventional O rings sitting in grooves in the liners.
Thde significant difference is that the National liner is 1/8" bigger in diameter at the top, both the shoulder and the machined area just below.
The RN liner has diameters here of 5.125" and 4.875", while the National uses 5.25" and 5".
Both have the same 4.875" diameter for the lower landing.
The National arrangement is far better, as anyone who has had to pull corroded liners out of an old RN can tell you. Having the same diameter top & bottom can mean that force is needed all the way up, until the liner is pretty much clear of the top of the block.
Worse, with the conversion to O-ring seals, these have to be forced through the same diameter at the top, when fitting new liners, as the diameter they seal in at the bottom, and with no 'lead' to help them in, so there's a serious risk of the rings getting damaged before they even reach the bottom. That's not a problem with the National dimensions - the trouble is that National liners are to the best of my knowledge an extinct breed (someone will probably post now that they know where there's a shed full!).
The issue is how to make the RN liner fit properly into a National?
As with most engineering jobs, there will be more than one way to skin the cat, but this is what I did.
Why not use the tops of the old, worn, National liners as they already have the correct dimensions?
0.2" was removed from the lower face of the top shoulder of the new liners, this meant that the sleeve could have some useful strength with that 0.2" included.
These sleeves were fitted into place with Loctite 638 high strength retainer, though probably simply assembling into place with a good dose of Wellseal would have been fine.
Finished product:-
After cleaning out the sludge from the block, some lead was put onto the top of the lower landing to ease the entry of the O-rings:-
This pic shows the splash plates mentioned in my earier post, they sit on the ends of studs which also serve to compress the liner sealing gland (just about visible):-
Tim