This study paired the high-pressure pulsed waterjet process and plasma transferred wire arc technology to develop a technique to remanufacture worn-out cylinder bores and give new life to worn-out engines. Plasma transferred wire arc technology is currently being used for engine remanufacturing to deposit the top-coat. The idea behind this project is to eliminate the expensive nickel-aluminum pre-bond coat by optimizing the surface roughness profile of the substrate to provide acceptable mechanical bonding between the coating and substrate. In this study, low carbon stainless-steel was plasma spray coated on a range of pulsed waterjet roughened grey cast iron and cast aluminum A380 surface profiles. The roughened surfaces increased the adhesion strength between the substrates and stainless-steel coating. Limitations exist, such that, if the roughness profile generated was copious the coating mirrored the roughened surface profile. Additionally, if the roughness profile was insignificant the coating was completely removed during detachment-based failure.