Honda S2000 Closed Deck Conversion | F20C & F22C | EPOXY54
Seal the Open Deck.
Stop Bore Flex.
The F20C and F22C1 run 11:1 compression on open-deck aluminum with FRM composite sleeves. Under boost, the unsupported cylinder walls flex — ring seal goes first, head gaskets follow. EPOXY54 fills the open-deck gap and locks cylinder liner retention to closed-deck strength. No machining. No sleeves. No teardown beyond what you're already doing.
Get the Kit — $124.99Why the F20C / F22C Needs EPOXY54
Bore Flex Under Boost
The open-deck design leaves the top of each cylinder bore unsupported. Under boost pressure, the walls flex outward — the piston rings can't maintain a consistent seal against a moving bore, causing blowby, power loss, and rapid ring wear.
Head Gasket Failure Risk
Bore distortion puts uneven load on the head gasket. At 11.1:1 compression, detonation is already the primary risk above ~10 psi on pump gas — combine that with a flexing deck and head gasket failure becomes a matter of when, not if.
The Open-Deck Geometry
Honda used FRM (fiber-reinforced metal) composite sleeves instead of traditional iron liners — excellent for weight and heat transfer, but the open deck means those sleeves rely entirely on the head clamping them in place. Any bore movement is liner movement.
EPOXY54 Eliminates the Unsupported Deck Geometry — Without Machining
One kit fills the open-deck gap around all four cylinders, restoring lateral support to the FRM sleeves and bringing the block to closed-deck liner retention. The result is a stable bore under boost, consistent ring seal, and a head gasket that stays sealed.
Installation Overview
Prepare the Block
Fill the water jacket with a temporary solute like sugar or salt. This creates the void space for coolant passages while the epoxy is applied.
Mix & Pour Epoxy
Mix EPOXY54 and pour it to fill the top ¾" of the block. The runny consistency ensures a clean, seamless application.
Cure for 24 Hours
Allow the epoxy to cure completely. Unlike other closed deck solutions, EPOXY54 is ready in just 24 hours without the need for machining.
Drill Coolant Passages
Following your head gasket design, drill the necessary coolant passages through the cured epoxy.
Dissolve & Flush
Dissolve the temporary solute with water and flush it out, leaving behind a perfectly reinforced block with optimal cooling.
Open Deck vs EPOXY54 Closed Deck
| Factor | Stock Open Deck | EPOXY54 Closed Deck |
|---|---|---|
| Cylinder bore support at top | None — unsupported gap | Full lateral support via filled deck |
| Bore flex under boost | High — walls deflect under pressure | Eliminated — bore stays round |
| Ring seal stability | Compromised as bore flexes | Consistent across all RPM and load |
| Head gasket loading | Uneven — elevated failure risk | Even clamping load retained |
| Machining required | — | None |
| Cost | $0 (until it fails) | $124.99 — Inline 4 Kit |
Build Your S2000 Right — From the Block Up
Inline 4 Kit · Covers F20C & F22C1 · AP1 & AP2 S2000
Order EPOXY54Common Questions
Yes. Both the F20C (AP1, 2000–2003) and F22C1 (AP2, 2004–2009) share the same open-deck aluminum block architecture with FRM composite sleeves. The Inline 4 Kit covers both engines — one kit, one application process.
No machining is required. EPOXY54 fills the open-deck gap as-cast. The only preparation needed is a clean, dry deck surface — degrease the area thoroughly and the epoxy bonds directly to the aluminum and FRM sleeve material.
EPOXY54 is applied with the head removed — during a head gasket replacement, a full rebuild, or dedicated boosted build prep. It adds no extra teardown beyond what you're already doing with the head off the block.
The F20C runs 11.1:1 compression and the F22C1 runs 11.0:1 — both are high for a forced-induction application. That compression makes detonation the primary failure mode above approximately 10 psi on pump gas. Bore flex compounds the risk: a distorting cylinder creates inconsistent combustion conditions that increase knock sensitivity. Closing the deck with EPOXY54 stabilizes the bore, which helps manage combustion consistency alongside appropriate tune and fueling.
The Inline 4 Kit contains both parts of the two-part epoxy system, pre-measured for a four-cylinder block. It includes the volume needed to fill the open-deck gap on all four cylinders of the F20C or F22C1, along with application instructions.