yes you can just fill the entire block with cement and/or aluminum and run an external water pump to the head.

 

a tip so that if your not boreing it makes no machining needed with the devcon being i use it regularly to fill castings at work use spray wax on the deck and on a machined peice of steel or aluminum to make this perfect another small problem with devcon is that sometimes you get airbubbles and it will weakin the material al not very strong it gets rock hard but under heat and constant pressure it isnt a happy substance to work with im again gonna refer you guys to a local machine shop to have a custom block guard made or get a buddy that works at one to make it for you a cnc cut block gurd that modified with the drilled holes in it will be ver efficient make sure though that its made oversized to be pressed into place to avoid any movement and give you a solid cylinder wall
thats my $0.02 any one has any argument or anything i dont know in that let me know

 

Dude... punctuation.

 

well i'm gonna be doin this to my block soon. already got the devcon from grainger and got an account(by the way it's really easy, they only made me fill out the top portion of the paper: name, address, phone, business name...and i think that was it, i can only purchase with cash or card but that's good enough) anyways. i want to fill a little lower than the one inch from the top of the block, maybe 1.5 or 2 and i got some ideas

i was thinkin about puttin some bolts where the coolant holes are before i pour the devcon, then once it's done just reverse em out, see any problems with that?

next, how bad do you think a slightly greasy block would stink if i put it on the oven in my house for the 4 hrs at 200 degrees?

don't wanna stink up the house and don't wanna contaminate the oven or some ----( and hell yeah i live with my mom so it really matters, just gonna do it in the middle of the nite when she's sleepin, haha)

this will be a daily driver turbo hopin for about 200 to 250 hp with a del sol dual core radiator

 

if that's all you're lookin to be pushing for power, i wouldn't even worry about block filling

 

darksol, thanks for the link to the cheaper devcon. I ordered some up this week.

 

id just rather make sure i'm boostin safely and not risk gettin some cylinder warpage or somethin like that. i also already bought the devcon and might as well keep it and use it, but anyone think it'll stink in the oven?

 

It's odorless, but I dunno if it gives off bad fumes.

 

I've spent the last hour or so reading every word of this thread and absorbing as much of it as humanly possible. And I am now truly speechless! This just jumped to the front of the line on my to do list. Thanks guys, and of course I'll let you all know when I get it started and of course I'll take pics. I'll be ordering this stuff tomorrow.

 

same for me when I do my twincharging stage of my d16z6 this looks like this will save me around a grand.
No need for sleeving for 25 psi. thanks guys