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hotrex · 11-23-2005, 04:16 PM

heres the deal. filling a stock sleeve block to handle mucho boost for under 50 dollars.

the supplies.

1. DEVCON LIQUID ALUMINUM F-2 (1 lb ) for b series ( 3/4) lb for d series
2. BOX OF TABLE SALT.
3. 80 GRIT SAND PAPER.
4. CONTACT CLEANER
5. HACKSAW BLADE ( for measuring)
6. SHARPIE
7. 19MM WRENCH
8 BEER ( optional)
9. funnel
10. level

HERE ARE THE STEPS

1. gather all supplies, listed above.

2. put block on a level surface, make sure its level. if on a stand level the stand front to back and side to side.

3. take 80 grit sand paper and skuff the water jacket and sleeve so the devcon will bond when poured. after you sand it, spray with a contact cleaner to remove, oils, grit, ect.
4. take your hacksaw blade., this is your ghetto marking tool. place blade along sleeve where the water pump hole is. the end of the blade will be even with the top of the water pump hole. where the blade intersects with the deck draw a line.
that will be your measurement as to how far up to fill your jacket with salt.
5.pour salt evenly around the jacket until it meets your measurement you determine with your hacksaw measuring stick. be sure to take the blade and poke the salt to remove ait pockets and have it sit uniform.

6. after the salt is air pocket free and to the level you desire., mix your epoxy.
stir together for at least 4 minutes. after the mixture is a uniform grey color pour it through the funnel and into your jacket.

when its all poured it will look like this.

7. now after you pour the devcon, you will need to skim your finger around the top of the sleeve, to 1, even out the pour, and 2. smooth it out. and make sure none of it sits above the gaset surface. there should be a bit of sleeve uncovered at the very top, prob like 1/16 inch.

8. let the devcon sit for 4 hrs. at room temp. then for 4 hrs it must be cured at 200 degrees. i put the block and a space heater inside a big box and let it bake out. be sure to keep a close eye on it, uncase you light up the box. hehe

9. let sit for another 18 hrs after that.

10. after it is hard. take an old headgasket. lay it on top of the block, and mark the coolant holes with your sharpie.

11. drill holes in the devcon 1 size smaller than the hole in the headgasket.

12. once holes are drilled, remove the freeze plug with a 19mm.
13. take your hose, and flush the salt out of the sleeves until you see no more coming out and the water shoots out of the holes drilled in the devcon evenly.
14. replace drain plug, and oil cyl walls to prevent rust.
15. hone or bore block and assemble.

16. drinka beer to celebrate your 50 dollar filled block and all the hard boost it will endure.

brought to you by hotrex da stallion drinker.

Updated by Moderator:

A honda-tech thread link is given to show some negative results possibly resulting from the DIY blockguard.
http://honda-tech.com/zerothread?id=1444721&page=21
There is no direct evidence supporting the argument that the use of the devcon blockguard was the ONLY reason for failure, but do this modification at your own risk, as can be suggested for any engine modifications.

phyregod · 11-23-2005, 05:18 PM

Awesome. We need to get this in the tech section fo shizzo.

wanderinman · 11-23-2005, 09:42 PM

Wasn't there a writeup on this a few months back? At any rate, good info, might try it on my next motor.

Calesta · 11-23-2005, 10:23 PM

[img]style_emoticons/<#EMO_DIR#>/icon_moved.gif[/img]

Great job on the writeup!

pissedoffsol · 11-25-2005, 12:01 PM

made it to our front page [img]style_emoticons/<#EMO_DIR#>/tongue.gif[/img]

http://hondaswap.com/

Calesta · 11-26-2005, 09:43 PM

Cool- about time something else got posted up there. [img]style_emoticons/<#EMO_DIR#>/smile.gif[/img]

11-23-2005, 04:16 PM	#1
hotrex Senior Member Join Date: Sep 2005 Posts: 548 iTrader: 0 / 0% Rep Power: 12	heres the deal. filling a stock sleeve block to handle mucho boost for under 50 dollars. the supplies. 1. DEVCON LIQUID ALUMINUM F-2 (1 lb ) for b series ( 3/4) lb for d series 2. BOX OF TABLE SALT. 3. 80 GRIT SAND PAPER. 4. CONTACT CLEANER 5. HACKSAW BLADE ( for measuring) 6. SHARPIE 7. 19MM WRENCH 8 BEER ( optional) 9. funnel 10. level HERE ARE THE STEPS 1. gather all supplies, listed above. 2. put block on a level surface, make sure its level. if on a stand level the stand front to back and side to side. 3. take 80 grit sand paper and skuff the water jacket and sleeve so the devcon will bond when poured. after you sand it, spray with a contact cleaner to remove, oils, grit, ect. 4. take your hacksaw blade., this is your ghetto marking tool. place blade along sleeve where the water pump hole is. the end of the blade will be even with the top of the water pump hole. where the blade intersects with the deck draw a line. that will be your measurement as to how far up to fill your jacket with salt. 5.pour salt evenly around the jacket until it meets your measurement you determine with your hacksaw measuring stick. be sure to take the blade and poke the salt to remove ait pockets and have it sit uniform. 6. after the salt is air pocket free and to the level you desire., mix your epoxy. stir together for at least 4 minutes. after the mixture is a uniform grey color pour it through the funnel and into your jacket. when its all poured it will look like this. 7. now after you pour the devcon, you will need to skim your finger around the top of the sleeve, to 1, even out the pour, and 2. smooth it out. and make sure none of it sits above the gaset surface. there should be a bit of sleeve uncovered at the very top, prob like 1/16 inch. 8. let the devcon sit for 4 hrs. at room temp. then for 4 hrs it must be cured at 200 degrees. i put the block and a space heater inside a big box and let it bake out. be sure to keep a close eye on it, uncase you light up the box. hehe 9. let sit for another 18 hrs after that. 10. after it is hard. take an old headgasket. lay it on top of the block, and mark the coolant holes with your sharpie. 11. drill holes in the devcon 1 size smaller than the hole in the headgasket. 12. once holes are drilled, remove the freeze plug with a 19mm. 13. take your hose, and flush the salt out of the sleeves until you see no more coming out and the water shoots out of the holes drilled in the devcon evenly. 14. replace drain plug, and oil cyl walls to prevent rust. 15. hone or bore block and assemble. 16. drinka beer to celebrate your 50 dollar filled block and all the hard boost it will endure. brought to you by hotrex da stallion drinker. Updated by Moderator: A honda-tech thread link is given to show some negative results possibly resulting from the DIY blockguard. http://honda-tech.com/zerothread?id=1444721&page=21 There is no direct evidence supporting the argument that the use of the devcon blockguard was the ONLY reason for failure, but do this modification at your own risk, as can be suggested for any engine modifications. __________________ www.cc-fab.net for all your turbo manifold and charge piping needs,

11-23-2005, 09:42 PM	#3
wanderinman Senior Member Join Date: Feb 2005 Location: Raleigh, NC Posts: 863 iTrader: 0 / 0% Rep Power: 16	Wasn't there a writeup on this a few months back? At any rate, good info, might try it on my next motor. __________________ 1991 Accord Sedan - 5 Speed Newest Project 96 LS Sedan - GETTING PARTED OUT - PM ME IF YOU WANT SOMETHING INSTALLED - 15" Bronze Ikon wheels w/ Kumho ASX tires, Eibach sportlines, DC Sports catback, greddy header, Bosch +4 plugs, brembo rotors, Hawk HPS pads, Exedy clutch Vouches: driverunknown, 97CTR

11-23-2005, 10:23 PM	#4
Calesta Admin with a big stick Join Date: Sep 2002 Location: Lufkin, TX Age: 30 Posts: 23,838 iTrader: 0 / 0% Ride: 2003 S2000 Rep Power: 265	[img]style_emoticons/<#EMO_DIR#>/icon_moved.gif[/img] Great job on the writeup! __________________ DO NOT PM me with tech questions! Use the forums! Intercrew Auto Salon - (972) 485-8688

11-26-2005, 09:43 PM	#6
Calesta Admin with a big stick Join Date: Sep 2002 Location: Lufkin, TX Age: 30 Posts: 23,838 iTrader: 0 / 0% Ride: 2003 S2000 Rep Power: 265	Cool- about time something else got posted up there. [img]style_emoticons/<#EMO_DIR#>/smile.gif[/img] __________________ DO NOT PM me with tech questions! Use the forums! Intercrew Auto Salon - (972) 485-8688

11-25-2005, 12:01 PM	#5
pissedoffsol RETIRED Join Date: Sep 2002 Location: Retirement Home Age: 28 Posts: 49,974 iTrader: 2 / 100% Ride: Electric Scooter Blog Entries: 1 Rep Power: 529	made it to our front page [img]style_emoticons/<#EMO_DIR#>/tongue.gif[/img] http://hondaswap.com/

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WRITE-UP DIY BLOCK FILLING