Filling Block... How To.... UPDATED
 

ok, so this is basically common sense but here is a how to on what i did.

things that you need:

- stripped block of your choice
- epsom salt
- devcon liquid aluminum www.grainger.com ($45)


step 1:
make sure block is level (use a level on the deck)

step 2:
look to see that H2O drain plug is still in block, but loose

step 3:
w/ h20 pump removed, duct-tape up where the H2O pump was

step 4:
pour salt evenly into the H20 jacket

step 5:
take a screwdriver and find height just abovethe H2O pump hole and mark it on the screwdriver

step 6:
take screwdriver around jacket at predetermaned height to make the salt even

step 7:
mix proper ammount of devcon liquid aluminum about 3/4lb

step 8:
pour slowly (leaving approx 3/16" from deck) ***take finger and run around jacket removing excess... works well***

step 9:
let cure at room temp for 2 hours and the at 200* for 4 hours. what i did was put the block over a heat vent and shut the rest in the house. so it was basically F.I. even before it was in the car 8) then after 4 hrs w/ heat, let stand @ room temp for 18 hrs

step 10:
pull drain plug after 24 hours (full cure time) and run water thru it to remove salt (at least 5 minutes) remember to spray WD40 in bores after H20

step 11:
put "new" gasket on top of block and mark it w/ a sharpie where the coolant holes go

step 12:
use a undersized drill (1/8") to make a "pilot hole" and on the slots, drill 2 holes for the outside radai of each slot

step 13:
goto larger sized drill and open up the holes, and slots

step 14:
blow out block after drilling then rinse w/ H20, respray WD40 in bores

step 15:
macine work, have it honed or bored or whatever

step 16:
rebuild
http://img.villagephotos.com/p/2004-...Picture200.jpg
http://img.villagephotos.com/p/2004-...Picture201.jpg
http://img.villagephotos.com/p/2004-...Picture209.jpg


now, here's the thing....
i want to dispell the myth about the overheating issue....
if done right, you will have no problems at all.
i have drove my car for 100 miles so far w/ no T-stat and the gauge hasn't went above C. i also can just barely feel any heat comming out of the vents. so if worse come to worse, and you are getting hot w/ the T-stat installed, remove it and you will see a temp drop.

good luck!
mike

Re: Filling Block..... How To
 

Nice write up. I may try it now!

Re: Filling Block..... How To
 

i'm gonna use the block filler that summit racing sells...is it basically the same stuff?? i know it's a few buck cheaper so i didn't know if there's much of a difference in contents

Re: Filling Block..... How To
 

Absolute post up a link for that please.

Re: Filling Block..... How To
 

http://store.summitracing.com/defaul...=egnsearch.asp

it ends up costing about 21 bucks because of hazardous shipping

Re: Filling Block..... How To
 

Driving without a T-stat is bad, that isn't an option. Good write-up, I have thought about this a lot.

Re: Filling Block..... How To
 

can't you just get a t-stat that opens at a cooler temp?

Re: Filling Block..... How To
 

What is snow salt? and where do I get it? is it the same as rock salt you use on your driveway in the winter?

Re: Filling Block..... How To
 

yes rock salt is snow salt

Re: Filling Block..... How To
 

this is gonna sound dumb but how do you get the salt to stay in block?