EPOXY54, The Aluminum Block Epoxy Kit

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Key Benefits of Our Custom Epoxy Formula:

Thermal Compatibility:

• Engineered with a thermal expansion rate closely matching aluminum for long-term stability.
• Unlike cement alternatives that expand and shrink during curing, our epoxy is non-expanding and non-shrinking.
• Prevents piston clearance issues and preserves cylinder integrity.

Permanent Bonding:

• Specifically designed to adhere permanently to aluminum.
  

Easy Installation:

• Runny consistency ensures a clean, seamless application.
• Can be applied before or after machine work without affecting dimensional accuracy.

Why Epoxy?

Pros:

• Cost-effective: Significantly cheaper than alternatives.
• DIY-friendly: No machining required (deck surfacing remains untouched).
• High strength: 21,000 psi compressive strength.
• Specially formulated: Optimized for aluminum blocks.
• Quick drying: Cures in just 24 hours.
• Retains cooling system: Stock cooling properties are preserved.
• Durable: Chemical-resistant to coolant, ensuring longevity.
• Daily driveable: Suitable for both street and track use.

Cons:

• Aesthetic simplicity: May not look as polished as aluminum.

How Does It Compare to Alternatives?

• Unlike cement or other fillers, epoxy does not deteriorate or erode over time.
• With chemical resistance to coolant, it ensures reliability for the long haul.

Proven Performance Across Platforms

• The fastest aluminum-block engines in the ¼ mile rely on epoxy to reinforce their blocks, proving its capability under extreme power and stress.
• Trusted and tested across various platforms, including VQ, Volvo, BMW, Subaru, and Top Fuel Drag Bikes.
• Customer-Proven Results: Real-world applications demonstrate unmatched durability in high-performance environments.
• Watch the Stress Test: A customer review highlights the epoxy’s strength under extreme conditions: Stress Test Video.

Daily Drivability & Performance

• Designed to maintain stock cooling efficiency, comparable to CSS blocks or closed deck platforms.
• Ideal for high-performance and everyday use, with no compromise on cooling or engine longevity.

Installation Made Simple

1. Fill the block with a temporary solute (e.g., sugar or salt).
2. Pour the high-temperature, 2-part epoxy to fill ¾'' of the block.
3. Allow it to dry for 24 hours.
4. Drill coolant passages according to the head gasket design.
5. Dissolve the solute with water, leaving behind a durable, custom-fit epoxy layer.

Complete instructions and an installation video are included with every kit: Watch the Installation Video.

Proven Technology

Whether you’re building a performance engine or looking to reinforce an aluminum block for longevity, our epoxy offers an affordable, reliable alternative to traditional solutions.

Ideal for aluminum engine blocks of all kinds, this epoxy supports higher power levels, improves cylinder longevity, and maintains daily drivability—all at a fraction of the cost of closed-deck alternatives.

Cast Iron Applications:
While EPOXY54 was originally formulated to match the thermal expansion characteristics of aluminum blocks, we do have many customers successfully using it in cast iron applications as well. These include small block Chevys, 2JZ-GTEs, LS variants, top fuel drag bikes, and others. In fact, in most aluminum blocks the cylinder liners themselves are cast iron, which is why the product can still perform well in these environments.

ATTENTION: DRY BLOCK USERS

For full dry block applications, required volume can vary significantly depending on bore size, coolant jacket depth, and overall block design. Because of this, we strongly recommend measuring your engine’s water jacket volume before installation.

To do this, seal off the water ports and fill the coolant jackets with a measured amount of water. The volume of water used will directly reflect the amount of material required. This ensures you have sufficient product and avoids coming up short during your fill.

For convenience, we offer standardized DRY BLOCK kit sizes based on common engine configurations:

• Inline 6: 1080 ml

• Inline 5: 1080 ml

• Inline 4: 600 ml

• Inline 3: 540 ml

• V6: 2 × 300 ml (one per bank)

• V8: 2 × 1080 ml (one per bank)

• V10: 2 × 1200 ml (one per bank)

• Flat 4: 1080 ml

• Flat 6: 1200 ml

• Cylinder Head: 1080 ml

• Small Displacement Engines: 540 ml

These quantities are based on typical full-fill requirements, but variations between engine platforms can occur. Measuring beforehand is always the most accurate approach.

If you are unsure, feel free to reach out before ordering—we’re happy to help ensure you get the correct amount.

Made in USA