Very interesting suggestion, bigben2k... the amount of deformation that would occour using a hot tool is probably unacceptable, however. Nevertheless, howe about drilling, then inserting a hot pin that is a couple of thousands wider than the drill? This would melt shut any big cracks and completely erradicate smaller ones!
On a sidenote, I took my block up to 150 psi last night (yeah, i know i'm crazy) and it's absolutely rock solid at 150 psi for over 12 hours now... nor preassure drop, no observable deformation, no cracks.
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