Go Back   Honda-Tech > Honda and Acura Technical Forums > Welding/Fabrication
Sign in using an external account
Register Forgot Password?
Search


Welcome to Honda-Tech!
Welcome to Honda-Tech.com.

You are currently viewing our forums as a guest, which gives you limited access to view most discussions and access our other features. By joining our community you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is fast, simple and absolutely free so please, join the Honda-Tech community today!


Reply
 
 
 
submit to reddit
 
Thread Tools Search this Thread
Old 11-24-2005, 09:38 PM   #1
ccfab
Garage is empty, add now
 
Join Date: Jul 2005
Location: somewhere in, ct
Posts: 778
iTrader Rating: (0)
Default diy filled b series block, with writeup, comments welcome

heres the deal. filling a stock sleeve block to handle mucho boost for under 50 dollars.
full info on devcon here
http://www.devcon.com/techinfo/108.pdf

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. FUNNEL
8 BEER ( optional)
10. LEVEL

HERE ARE THE STEPS

1. gather all supplies, listed above.
Click the image to open in full size.
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.
Click the image to open in full size.
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.
Click the image to open in full size.
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.
Click the image to open in full size.
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.
Click the image to open in full size.

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.
Click the image to open in full size.

brought to you by ccfab da stallion drinker.


Modified by ccfab at 11:58 PM 11/24/2005
ccfab is offline   Reply With Quote
Old 11-24-2005, 09:55 PM   #2
Cimburke23
Honda-Tech Member
Garage is empty, add now
 
Cimburke23's Avatar
 
Join Date: Jul 2004
Location: JDM is the NEW RICE, VA, USA
Posts: 1,287
iTrader Rating: (0)
Send a message via AIM to Cimburke23
Default Re: diy filled b series block, with writeup, comments welcome (ccfab)

so how much boost do u think this will hold? have u tested it to see how much whp u can make? Click the image to open in full size. to this plan though, def. beats $1000 sleeve job Click the image to open in full size.
Cimburke23 is offline   Reply With Quote
Old 11-24-2005, 09:57 PM   #3
wantboost
TAKE YO PANTIES OFF!
1991 Nissan 240SX
My Garage
 
wantboost's Avatar
 
Join Date: Jul 2004
Location: Georgia, USA
Posts: 17,847
iTrader Rating: (2)
OneAgainstTheWorld The HOONIGANS
Send a message via AIM to wantboost
Default Re: diy filled b series block, with writeup, comments welcome (ccfab)

looks good...

but because of the salt the devcon will now pour past the salt... in effect its like a blockguard
__________________
In Loving Memory of Kaelan Stein

August 14, 1992 - April 16, 2014

Left this life way too young but we will never forget you.

wantboost is offline   Reply With Quote
Old 11-24-2005, 10:00 PM   #4
ccfab
Garage is empty, add now
 
Join Date: Jul 2005
Location: somewhere in, ct
Posts: 778
iTrader Rating: (0)
Default Re: diy filled b series block, with writeup, comments welcome (wantboost)

yes, it fills approx 1.5 inches of the sleeve. then it is drilled.

i would definately call it a hmt block guard.

blacksi on hmt ran a simialr setup for 2 yrs in his drag car making 470ish whp at 32 psi on a t4/60-1

it has been run time and time again,

i will personally be taking this block into the 20-25 psi range to see what happens

there are also numerous people daily driving these filled blocks with no overheating issues whatsoeever Click the image to open in full size.
ccfab is offline   Reply With Quote
Old 11-24-2005, 10:01 PM   #5
ccfab
Garage is empty, add now
 
Join Date: Jul 2005
Location: somewhere in, ct
Posts: 778
iTrader Rating: (0)
Default Re: diy filled b series block, with writeup, comments welcome (ccfab)

also, the devcon is of a thick consistency, and does not pour past the salt.

you must pack the salt in as tightly as possible. thats why i used table salt and not rock salt like some use.

it is much finer and packs together much tighter
ccfab is offline   Reply With Quote
Old 11-24-2005, 10:05 PM   #6
wantboost
TAKE YO PANTIES OFF!
1991 Nissan 240SX
My Garage
 
wantboost's Avatar
 
Join Date: Jul 2004
Location: Georgia, USA
Posts: 17,847
iTrader Rating: (2)
OneAgainstTheWorld The HOONIGANS
Send a message via AIM to wantboost
Default Re: diy filled b series block, with writeup, comments welcome (ccfab)

ah, better than a blockguard then... that .5" inch piece of metal is a joke... this stuff is thikcer and it wont distort sleeves... im gonna try this with my d-series boosted go kart
__________________
In Loving Memory of Kaelan Stein

August 14, 1992 - April 16, 2014

Left this life way too young but we will never forget you.

wantboost is offline   Reply With Quote
Old 11-24-2005, 10:16 PM   #7
LSturboHB
Garage is empty, add now
 
LSturboHB's Avatar
 
Join Date: Dec 2001
Location: Riceville, usa
Posts: 590
iTrader Rating: (0)
Send a message via AIM to LSturboHB
Default Re: diy filled b series block, with writeup, comments welcome (wantboost)

interesting, gotta love the backyard specials Click the image to open in full size.
__________________

old civic :
[url="http://groups.msn.com/TurboLSHatchback/newpics.msnw"]http://groups.msn.com/TurboLSHatchback/newpics.msnw[/url]
LSturboHB is offline   Reply With Quote
Old 11-25-2005, 12:15 AM   #8
.RTErnie
Honda-Tech Member
Garage is empty, add now
 
.RTErnie's Avatar
 
Join Date: May 2002
Location: BeLlInGhAm, Wa
Posts: 3,599
iTrader Rating: (0)
Send a message via AIM to .RTErnie
Default Re: diy filled b series block, with writeup, comments welcome (ccfab)

Quote:
Originally Posted by ccfab
it is much finer and packs together much tighter
Click the image to open in full size. Click the image to open in full size.
__________________
Eric Urness
R/TErnie Race Engineering
541 980 6022
.RTErnie is offline   Reply With Quote
Old 11-25-2005, 02:15 AM   #9
elitesi8
Junior Member
Garage is empty, add now
 
elitesi8's Avatar
 
Join Date: Jun 2004
Location: EM1ville
Posts: 617
iTrader Rating: (0)
Default Re: diy filled b series block, with writeup, comments welcome (RTErnie)

Gets my vote for the MacGyver award! Click the image to open in full size. Click the image to open in full size. Click the image to open in full size.
__________________
EM1 Crew Member #85
AMR connoisseur
For Sale: Mint AMR coilovers for EM1, only driven 3 weeks and about 150 miles PM ME!! http://images.honda-tech.com/set1/smile/emwink.gif

If you don't stand BEHIND our troops... feel free to stand IN FRONT of them!!
elitesi8 is offline   Reply With Quote
Old 11-25-2005, 06:07 AM   #10
thermal
Honda-Tech Member
Garage is empty, add now
 
thermal's Avatar
 
Join Date: Aug 2001
Location: VA BEACH
Posts: 1,060
iTrader Rating: (0)
Send a message via AIM to thermal
Default Re: diy filled b series block, with writeup, comments welcome (elitesi8)

another one from the boys of HMT! Great stuff! Click the image to open in full size. Click the image to open in full size.
__________________
96 integra GSR, B18C-R, GT35R, AEM EMS, 534.67 @ 22 psi pump gas <-- SHAD tuned
thermal is offline   Reply With Quote
Old 11-25-2005, 08:09 AM   #11
blueoval557
Junior Member
Garage is empty, add now
 
blueoval557's Avatar
 
Join Date: Jul 2004
Location: Sacramento, CA, USA
Posts: 526
iTrader Rating: (0)
Send a message via AIM to blueoval557
Default Re: diy filled b series block, with writeup, comments welcome (thermal)

This is nothing new. Some know I am not really into the import scene, but very much into the domestic stuff. Filling blocks is really nothing new. Does it help...? ABSOLUTELY. In a domestic block you just fill the water passages up normally to the freeze plugs, sometimes all the way up. We run ours on methanol so no water is needed, so all our blocks are filled. It greatly strengthens the block itself. I cant give you a number for boost, but know when you have a 4.75" stroke billet steel crank swinging around in there at 7500+ RPM, you need as much strength as you can get....and we've never had any problems with it.
Kyle
__________________
Curley's Racecars and Components

curleyscustomfab@comcast.net

916-397-3465
blueoval557 is offline   Reply With Quote
Old 11-25-2005, 08:24 AM   #12
wade
Honda-Tech Member
Garage is empty, add now
 
wade's Avatar
 
Join Date: Mar 2003
Location: Louisville, KY, USA
Posts: 3,667
iTrader Rating: (1)
Send a message via AIM to wade
Default

thumbsup
__________________
Arturbo (8:16 PM 3/6/2006): Well I assure you, I am tighter than anyone else out there.
AutoLab of Louisville, KY
Flamenco-T @ Fast-Turbo
ARTurbo
Tony1 @ T1 MotorSports
wade is offline   Reply With Quote
Old 11-25-2005, 08:51 AM   #13
gotboostedvr6
Honda-Tech Member
Garage is empty, add now
 
gotboostedvr6's Avatar
 
Join Date: Sep 2004
Location: east tri state, us
Posts: 3,431
iTrader Rating: (0)
Send a message via AIM to gotboostedvr6
Default Re: (wade)

i saw this write up on d-series.org
im very impressed
has anyone else on here used this w/o any cylinder wall issues?
__________________
I saw some black kid with g-unit spinner chain, and he was like ge-ge-ge-ge-geun... and before he finished i said "shut the [freak] up" and then he was like "Yo ray ray, this little white boy is messing wit me" then i made like the country Iraq invaded, IRAN.
gotboostedvr6 is offline   Reply With Quote
Old 11-25-2005, 10:26 AM   #14
AspectIndustries
Honda-Tech Member
Garage is empty, add now
 
AspectIndustries's Avatar
 
Join Date: Sep 2003
Location: Boost is good
Posts: 3,167
iTrader Rating: (0)
Default Re: diy filled b series block, with writeup, comments welcome (ccfab)

interesting. Click the image to open in full size.
__________________
I &lt;3 Boost!
AspectIndustries is offline   Reply With Quote
Old 11-25-2005, 04:20 PM   #15
mrbsponge
Honda-Tech Member
Garage is empty, add now
 
mrbsponge's Avatar
 
Join Date: Aug 2003
Location: TDCperformance.net
Posts: 4,098
iTrader Rating: (0)
Send a message via AIM to mrbsponge
Default

i have actually seen some V8 guys fill thier blocks completely with concrete, but these were on mud racers that only drive for about 10 seconds tho
__________________
Lexus SC300 B/W S366 9.51@146 Drag Radial Street Car
Top Dead Center Performance(www.tdcperformance.net)
Mobile Alabama, 251-661-6067, Neptune Dealer/Tuner
mrbsponge is offline   Reply With Quote
Old 11-25-2005, 05:01 PM   #16
LD_EGSICK
Honda-Tech Member
Garage is empty, add now
 
LD_EGSICK's Avatar
 
Join Date: Apr 2002
Location: va, USA
Posts: 657
iTrader Rating: (0)
Send a message via AIM to LD_EGSICK
Default Re: (mrbsponge)

some thign new to try out Click the image to open in full size.
__________________
Living Dreams Auto Salon LLC - Prayoonto Racing
R.I.P Nate Davis(East Coast Honda) 11/24/03 still living your dreams.
2007 Import Vs Domestic @MIR All Motor Street Class Winner.
LD_EGSICK is offline   Reply With Quote
Old 11-25-2005, 05:12 PM   #17
pythoner
Honda-Tech Member
Garage is empty, add now
 
pythoner's Avatar
 
Join Date: Jul 2005
Location: St. marys, GA, us
Posts: 1,325
iTrader Rating: (0)
Send a message via AIM to pythoner
Default

how easy is ti to mess up the block doing this? I am thinking of building a big boost motor and was interested..

THanks
Stephen
__________________
White 92 Civic CX (Kinda Stock)
White 02 Civic SI ( My daily driver ) EP3 Squad #44
pythoner is offline   Reply With Quote
Old 11-25-2005, 05:18 PM   #18
ccfab
Garage is empty, add now
 
Join Date: Jul 2005
Location: somewhere in, ct
Posts: 778
iTrader Rating: (0)
Default Re: (pythoner)

if you have any shred of patience and common sense, i cant see anyone ever messing up this install
ccfab is offline   Reply With Quote
Old 11-25-2005, 08:04 PM   #19
RCautoworks
B*a*n*n*e*d
Garage is empty, add now
 
Join Date: Nov 2002
Location: Illinois
Posts: 17,217
iTrader Rating: (0)
Send a message via AIM to RCautoworks
Default Re: diy filled b series block, with writeup, comments welcome (ccfab)

Does the salt have to be kosher Click the image to open in full size.
RCautoworks is offline   Reply With Quote
Old 11-25-2005, 08:09 PM   #20
tony1
Honda-Tech Member
Garage is empty, add now
 
tony1's Avatar
 
Join Date: May 2002
Location: Dallas, TX, USA
Posts: 15,811
iTrader Rating: (0)
Default Re: (ccfab)

Quote:
Originally Posted by ccfab
if you have any shred of patience and common sense, i cant see anyone ever messing up this install
Ahh, and there in lies the problem! lol
tony1 is offline   Reply With Quote
Old 11-25-2005, 08:19 PM   #21
wantboost
TAKE YO PANTIES OFF!
1991 Nissan 240SX
My Garage
 
wantboost's Avatar
 
Join Date: Jul 2004
Location: Georgia, USA
Posts: 17,847
iTrader Rating: (2)
OneAgainstTheWorld The HOONIGANS
Send a message via AIM to wantboost
Default Re: (tony1)

lol... good point

common sense isnt so common, nor is patience
__________________
In Loving Memory of Kaelan Stein

August 14, 1992 - April 16, 2014

Left this life way too young but we will never forget you.

wantboost is offline   Reply With Quote
Old 11-25-2005, 08:20 PM   #22
pro547
Junior Member
Garage is empty, add now
 
pro547's Avatar
 
Join Date: May 2004
Location: Columbus, Oh, USA
Posts: 248
iTrader Rating: (0)
Send a message via AIM to pro547
Default

I'm going to try this when I get my spare y7... I hope to get about 18psi out of my t3 with this setup....
__________________
1996 Civic CX HB D16Y7
Turbo T3
BMC log manifold
Custom aluminum IC piping
Open DOWNPIPE http://images.honda-tech.com/set1/smile/emsmilep.gif
DIY JDM lights
pro547 is offline   Reply With Quote
Old 11-25-2005, 08:41 PM   #23
ATS*Mark
OG triple OG
Garage is empty, add now
 
ATS*Mark's Avatar
 
Join Date: Mar 2002
Location: Norcal
Posts: 27,600
iTrader Rating: (0)
Send a message via AIM to ATS*Mark
Default Re: (pro547)

why does this work better than a block guard or does it?
__________________
I'm Still Hella_JDM
ATS-GARAGE.COM
EK SQUAD - REDZONE - MODACAR - Weaksauce - MEMORYFAB- JDMtheory
ATS*Mark is offline   Reply With Quote
Old 11-25-2005, 09:04 PM   #24
wantboost
TAKE YO PANTIES OFF!
1991 Nissan 240SX
My Garage
 
wantboost's Avatar
 
Join Date: Jul 2004
Location: Georgia, USA
Posts: 17,847
iTrader Rating: (2)
OneAgainstTheWorld The HOONIGANS
Send a message via AIM to wantboost
Default Re: (Hella_JDM)

more metal to support the sleeves, doesnt require pressor file fitting like a blockguard so it wont/cant distort the sleeves.
__________________
In Loving Memory of Kaelan Stein

August 14, 1992 - April 16, 2014

Left this life way too young but we will never forget you.

wantboost is offline   Reply With Quote
Old 11-25-2005, 09:08 PM   #25
ATS*Mark
OG triple OG
Garage is empty, add now
 
ATS*Mark's Avatar
 
Join Date: Mar 2002
Location: Norcal
Posts: 27,600
iTrader Rating: (0)
Send a message via AIM to ATS*Mark
Default Re: (wantboost)

true but he suggested to bore/rehone after the fill thats why i was wondering. why not fill all the way up and drill all the way down?
__________________
I'm Still Hella_JDM
ATS-GARAGE.COM
EK SQUAD - REDZONE - MODACAR - Weaksauce - MEMORYFAB- JDMtheory
ATS*Mark is offline   Reply With Quote
 
 
 
submit to reddit
Reply

Tags
aluminum, bars, block, bseries, diy, fill, filling, fwd, guard, homemade, honda, liquid, plug, series, size, traction

Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Forum Jump



All times are GMT -8. The time now is 11:54 PM.



2008 Copyright, InternetBrands Inc.
Powered by vBulletin® Version 3.7.4
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.

Honda and the Honda marquee are registered trademarks of the American Honda Motor Company, Inc. Neither American Honda Motor Company nor its subsidiaries or affiliates shall bear any responsibility for Honda-Tech.com content, comments, or advertising. Honda-Tech.com is not affiliated with American Honda Motor Company in any way. American Honda Motor Company does not sponsor, support, or endorse Honda-Tech.com in any way. Copyright/trademark/sales mark infringements are not intended or implied.
Emails & Contact Details