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?

Re: Filling Block..... How To
 

step 3

Re: Filling Block..... How To
 

hmm another dumb questions. how far down do you fill with the block filler? i kno how far from the top but how far down do you go?

Re: Filling Block..... How To
 

So what are the positive benefits of this vs... running a blockgaurd.

Re: Filling Block..... How To
 

A block guard supports the sleeves in the wrong place, the top. Cylinders need support where lateral loading is greatist, the middle. Blockguards hinder heat transfer where you need it most, at the top.

Re: Filling Block..... How To
 

exactly, the point that the cyl walls need the most support is in the upper 2 inches. but we are limited to that on the filling process to 1 1/2 inch below the deck because of the water pump.

check out www.theoldone.com and search for "block posting" larry is a honda genius and gives a write up on the block posting procedure, and the weak points of the honda block.

i posted my first block and had absolutely no problems w/ it @ 15psi. but the head-lifting owned me.

i just decided to do the filler to see how it works.... i know.... kinda crazy, but what the hell, right? someones gotta give some real world testing feedback.


hey whitey, how bout a sticky?

mike

Re: Filling Block..... How To
 

Jeez I'm the mod here ::). Another nice write up.

Re: Filling Block..... How To
 

oops, sorry chris.... forgot that i was'nt in GD :-X

just wait till i do the write up on the "easy to read honda compressor maps"

you muthafuckas are gonna flip!

late
mike

Re: Filling Block..... How To
 

do you thinking combining blockposts and the filler would have any positive affects? me and my brother want to do a ghetto d15 build this summer for fun, just looking for different options

Re: Filling Block..... How To
 

it might block water flow if you use the post and filler if the water passages where in the way of the post but you bastered you trying to copy me i'm doing a getto d15 build this summer lol but any way do you thank it took over a gallon to do the block?

Re: Filling Block..... How To
 

woah, whoa!!!!!!!

a gallon? you are only suppose to fill the upper 1 1/2 inches of the cylinder walls !!!!!!!!!!!!!!!

that's like 1 cup of filler!

go rearead the how-to

Re: Filling Block..... How To
 

so only the upper part of the cylinder walls are reenforced with the block filler stuff?? not the bottom? hences why you use the salt, right>?

Re: Filling Block..... How To
 

correct

Re: Filling Block..... How To
 

Excellent writeup! Once I get a spare block to build I will be filling it. Please keep us updated as to how its running!ated as to how its running!

Re: Filling Block..... How To
 

Keep us up to date on this when it comes to daily driving. If its fairly good for engine temps I might do this next winter during my buildup because I doubt I will be able to afford sleeves. I was going to post the block, but if this works better!

Re: Filling Block..... How To
 

late spring, early summer i might be able to tell you how daily driving is. temps right now are stupid here..... 22 was the high today. i don't even want to take my honda out in that kind of weather! i'll keep u guy's updated tho! march 26 the track opens up.... watch out!!!!! 15psi boyyyyeeee~

Re: Filling Block..... How To
 

What PSI Do you think a filled block can handle? Didn't beau's hold 33psi on the dyno?

Re: Filling Block..... How To
 

even tho its a single cam can't it handle more? like maybe 20? and if i did this to my ls block with forged pistons with crower rods or something could it handle like 15 daily with 20 on the track?

Re: Filling Block..... How To
 

i just don't want to max out my turbo.... i did the math and it starts to lose its efficiency badly @ around 17psi.

Re: Filling Block..... How To
 

I have a spare block and want to try this. I want to do it but im worried about overheating, and wasteing a build, keep updatas man looking foward to it.Looks good ;)

Re: Filling Block..... How To
 

put t-stat in it tonite, and it stayed in the normal temp range for the 10 miles i drove it.....it has heat now, thats a good thing, and it also don't run in open/closed loop anymore!!! give me a week, weather permitting, to test it out in realworld conditions... (making her scream)

mike

Re: Filling Block..... How To
 

Awsome, I might try to find a spare DOHC ZC block locally now to start my build up!

Re: Filling Block..... How To
 

yup yup, d series sleeves are probably just as strong as his b16 sleeves too.

Re: Filling Block..... How To
 

So a a d-series held 33psi with the block be filled? What setup did it have?

If you want to bore the cylinders would that have to be done before the block is filled? Can the filling be done and a block guard be used also?

CRX304- would you be willing to do this for someone? To a LS or B20 block? And then ship it?

Re: Filling Block..... How To
 

first...filling can be done before boreing, no blockguard is bad..just ask dr.boost...he's the world best block guard hater..

Re: Filling Block..... How To
 

His writeup isn't that difficult to read and do. Just as long as you understand the concept behind filling your block your good. There is no need for a blockguard after you've filled your block. Thats the whole reason for the filler, instead of the blockguard (and a few other reasons).

Re: Filling Block..... How To
 

Gold Da.... yes i could do it for you, but it would cost more than u prolly want to spend...
you shipping me the bare block = $50
me filling and drilling it = $125 including materials
machine work (bore, deck, tanked) = $100
shipping it back = $50

total cost... approx $325


here's an update on the overheating issue..... i drove it all weekend. highway and city, 250 miles in 30degree weather... and it's still @ normal temps w/ t-stst installed! ;D

mike

Re: Filling Block..... How To
 

30 degree weather isnt ----, i wanna know how it does when its 80 out.

and no a d isnt what beau held 33psi in, it was a b16

Re: Filling Block..... How To
 

this is interesting..
gonna have to find another block and try this.

Re: Filling Block..... How To
 

freakin awesome.

Re: Filling Block..... How To
 

you can get it bored decked and tanked for 100??? the ------- machine shop around here sucks