Hello Paul,

  Here are four pictures of P-port and the in-housing injection holders.
This housing is one of several scrap housings I am machining to get the
entrance angle and component dimensions finalized. These four pictures
are from last August's work and don't show the finished bores yet.
The P-port will have an outer step bore similar to the injector holders.
I am extremely happy with the hardness and toughness of the DEVCON Al
product.  Only one trouble is the consistency is a little softer than
taffy so as you can see, it is easy to end up with inclusions.  If you
work fast and use a technique like applying frosting on a cake, then
good results can be obtained.  Any hole can be drilled out and filled.
The company sells another slightly softer epoxy that pours.  I assume it
has more solvent in it.

I was very happy with how the injector area worked out and was able to
get the correct and final dimensions with this one housing.  As for the
P-port area I had to add about 6mm more along the bottom for the slide
throttle to be supported correctly.  For this test work, adding epoxy is
not a problem as it sticks to a preexisting epoxy when roughened up a
bit.  As you can see it sticks well to prepared alumunim and is damm
near as hard.  It machines VERY nice.

Can it done with your straight-in approach?   Yes why not?  Bend up some
thin aluminum sheet into the proper wedge profile.  Alodize it. Fix this
fence in place with hot glue gun on the outside.  Epoxy should be made
extra high and milled down to final dimensions. To save expensive epoxy
add a 40mm wooden or plastic dowel in the area where the inlet will be
bored.   DO NOT PREHEAT to make it easier to pour.  Follow the
directions for best results.

Doug in Japan

That 12.5 degree tilt looks like a real mechanical advantage.
I hope you can find a dyno over there to get some good numbers
on the pros and cons of your version. BSFC and HP.


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There are two Devcon products listed. Aluminum repair putty and pour.
I assume you used the putty. I'll get some and try it on a housing.
Did you use the yacht store aluminum conversion kit to prepare the surface?

I see DEVCON make no claims for high temperature performance.
Heat a puck sized chunk in the oven at 500 F and see what happens.
JB-Weld survives except it becomes softer and acts like a hard
rubber ball.

Paul Lamar