I'm currently in the process of spacing out some GSXR throttle bodies and I need to blank off the secondary butterfly and injector holes. I know that a lot of people use chemical metal but I've seen some pictures where this has failed and I don't like the idea of a lump breaking off and falling into the engine!

Looking round my garage earlier I noticed my hot glue gun - good for 193°C - might be a daft idea but I could make a nice bung with hot glue to fill the hole. If it overflowed a little to create a mushroom on the outside it couldn't fall in.

Any thoughts? Is this a daft idea?!

Personnally I think it won't last long. I had some aluminium plugs machined up had a step in diameter, with the bigger diameter so it couldn't fall in), then cooled them in the freezer and inserted with threadlock. Then just filed the protruding bits off. Looks really good, but I was able to get the machining done at work, not sure that would be an option anymore.

I used some roofing bolts with a large mushroom head glued in with epoxy same as a blank-pic in my archive secondary holes with liquid metal OK if done correctly

I think I'll get some spacers turned down to fill the holes, I just wanted to finish them and get them on so I could look at it!

Try some of these.
CORE PLUGS / FREEZE PLUGS 5 X 20MM CUP TYPE | eBay

They won't look as good as a turned down piece of aluminium, but they're cheap and easy. Check the size first, the ones I linked might not be right. You should be able to get some that are a nice squeeze in the hole, then secure them in with a bit of epoxy or silicone sealant.

[Edited on 15/4/13 by Furyous]