Featured

Filling D-Series Block, How To:

Comments Off 09 May 2009

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  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

Comments are closed.

Login



© 2010 Vitara Pistons. Hosted by GigaPros.

Web Design by Imburne Technical Advisors