The block fill must not shrink or expand during the curing period.Is filling a block with molten aluminum a good option? Or what is the usual filling material?
Aluminum will shrink as it solidifies and will expand more than the iron on engine warm up cycles.
As bubba posted, the block would need to be sonic tested for cylinder wall thickness.I saw a post about a filled block hemi 300 that was bored 4.125 so i was curious what the safest over bore would be with a semi block fill with coolant passages
Ok, this gives me a better idea of what to look for in doing work, do you think it would be possible to press in some copper tubes that go to the base of the water jacket and fill the block all the way up with it upside down and that way theres a small channel for coolant and allows water to flow into the head for normal cooling too? Would i need to draw a diagram to better explain what im thinkingAs bubba posted, the block would need to be sonic tested for cylinder wall thickness.
A block that has significant core shift during the casting process will have thin cylinder walls in places.
In a high performance application, the cylinder walls crack above the block fill line so the block would need to be completely filled.
A completely filled block with coolant running just through the head would probably not run cool enough for street use.
It would work well for drag racing especially with ethanol and methanol fuels.
Thats what i was meaning, with a small gap at the base of the water jacket to allow coolant to flow up to the headMy best guess is that wouldn't work very well since there would be no real circulation unless all the coolant passage were also connected together to each other at the bottom of the block too.