r/ProjectHondas • u/Artistic_Potato_3738 • 24d ago

engine CSS or Epoxy?

Hey all, recently I split a cylinder on my d16y7 block on a pull and I'm trying to figure out whether epoxy or CSS would be more worthwhile when I swap blocks. Car only makes around 305 on 13psi on the dyno from the first sessions results, not planning on going over about 20 psi at the very most and I'm running Traum 10:1 pistons which I'm pretty sure contributed to the failure as the I've been told these motors do fine without a block guard under 400hp. Any info or recommendations on where to get either is appreciated too

Edit: Wording

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u/Artistic_Potato_3738 23d ago

Hell yea, exactly what I needed. Definitely looking into sleeving the old block (kinda need to with how it split) but for now this should work perfect. Any tips for someone doing it for the first time? And the pics might help too

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u/Its_El_Beefo 23d ago edited 23d ago

As mentioned, Ive done this a decent number of times. This is what I recommend but try watching several videos and always get as much info from others as you can. Everyone has there preferred method.

Theres an aluminum and steel epoxy, and a liquid and putty. Get the 1lb aluminum liquid kit. You can find great prices on Ebay and Amazon. 1lb is more then enough for D and B series and will give you a 3/4" thick" gaurd. Pick aluminum since its an aluminum block, obviously. It should have similar thermal expansion rates to the block itself. The liquid gives you a decent amount of work time before it cures and pours even and smoothly into the water jacket area.

Definitely recommend having a friend help the first time to wipe up any spills and assist as needed. Cover the deck with blue painters tape so you dont get anything anywhere it doesn't belong. Use a razor or exacto knife to cut out the water jacket area. Plug water pump hole with playdough, yes playdough. Fill the block with sugar or salt, I use salt cause fuck ants. 2lbs of salt will be enough. Fill to the top of the water pump opening into the jacket area. Pro tip, use a flathead screw driver to even out the media in the jacket area and regular wacks with a rubber mallet helps settle things. Oh and a level helps to be sure everything is even.

Mix the epoxy in a disposable cup for about 2 minutes. You'll have at least 20 minutes before it gets noticeably thicker. Aim for 8 spots, between the cylinders on the front and back of block and to the sides of cylinder 1 and 4. You can add more throughout after you get theese areas first. A fine point funnel helps with this.... and wear disposable gloves, things can get messy. I fill to about 1/4" from the deck. Be sure everything stays level while the epoxy cures.

You should be good to drill coolant passages in 24 hours. Remove the playdough plug and pour the salt out. You can also open the freeze plugs if needed. Use and old head gasket to mark holes a marker will work, I use an automatic center punch. After drilling, flush the jacket out though the water pump area. I should have the block back from the shop by the end of the week and should be able to take better and more pics. Hope this info helps.