The invention discloses a cylinder bore surface profile and process. An engine block has a cylinder bore wall comprising a first portion having a first diameter and a second portion axially adjacent to the first portion having a second diameter greater than the first diameter. A series of parallel, circumferentially-extending grooves is formed in the second portion to roughen the surface and enhance adhesion of a later-applied, sprayed-on metallic coating. A non-masking section is formed between the first and the second portions to provide for a less-abrupt corner between the larger diameter and smaller diameter portions and eliminate any spray-masking that may otherwise. The non-masking section may be a flat or a curved chamfer. The non-masking section may be a non-grooved section of constant diameter.