Perhaps it might be easier to fabricate something along the lines of the Crosley Cobra engine rather than machine something out of billet aluminum...it would seem like you'd have a heck of a time with things like water jackets.
__________________ "We are forces of chaos and anarchy. Everything they say we are we are, and we are very proud of ourselves!" -- Jefferson Airplane
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I can tell you that these guys know a LOT about engines, and had to put a LOT of work into the R & D to make some production engines. Don't forget that these pretty much *have* to be made from castings, since the coolant passages are quite difficult (impossible?) to machine. It probably took a half a million dollars in R & D to make the first block, including the casting pattern. Once you have a pattern that works, the next ones will obviously be much cheaper. Of course after the blocks are cast, there is a lot of machine work.
Don't forget that these pretty much *have* to be made from castings, since the coolant passages are quite difficult (impossible?) to machine.
I was thinking more like an inline, so the coolant passages could just be "wallowed out" sections on the side with a cover bolted on.
Just think, if a serious group of engineers/marketers (with proper funding) set out to shatter the record for efficiency of the Atkinson cycle, then mass produced engines, with kits to install them in production cars (I think I'll stop dreaming before I get myself depressed).
Until this moment all that I have known
Is death's attempt at imitating life
And for the first time I am truly alive
-Becoming the Archetype