What is the material used to make the blocks? It feels like plastic. Where could I get it--as a 4X4 slab or something like that?

Thanks.

http://www.mcmaster.com/

You can make your own using print board. Laminate pieces up to the required thickness using 24hr epoxy and moderate clamp pressure to drive out excess glue, but not starve the joints.

Thanks--this will be very helpful, especially if my below experiment fails.

The block itself does not bare much load, right? It has to be airtight but that is basically it. As a test, I cast the block from alumilite plastic compount using the cracked original for moulding--that stuff is pretty hard and strong! Machines well too. According to specs, heat resistant to something like 400F. Seems like a good choice. Please let me know if it should not be used for this.

That sounds like it would work. I'd use a thick paper gasket as a thermal blocker. The intake shouldn't get too hot, it's cooled by the gas vaporizing.

Where do you get the stuff ("alumilite plastic compount")?

Hub Hobby (my LHS) sells it. They have a website too: http://www.alumilite.com/. Look at casting resins.

Excellent!!

I used some 1/8" plywood and West System to achieve my first homemade heat dam / insulator.

G10 board is another popular material used for carb blocks.

Chad