My coil packs went out on me on the dyno. Needless to say I was a little upset. So I started to search for a fix cause I'm cheap! LOL! All I could find was the old 3m tape trick. So I tried that and it worked for a little while. Then about 4-5 days later low and behold they started the same crap again!
At this point I was about to bite the bullet and spend the money on Split fire coils. Before I did, I wanted to pull the coils out and see exactly what was going on! They were firing threw their plastic housing! There were small, I mean SMALL cracks in the plastic housings on about 4 of the coils. I hooked them up and started the car up and turned out all the lights in the shop! Talk about a light show!!
This told me the coils themselves were actually working! It was just that there housings had failed. I'm a Honda tech by trade and I've seen a countless number of internal coils on Hondas go out due to the heat that they endure being inside of the distributor. Now on the Honda models that have the coil on the outside of the distributor away from all the heat, they never have a problem. Long story short it does appear to be a failure in the coil housing due to heat.
So I set out to see if I could remedy the housing problem. (Since the coils still seemed to be firing good.)
I looked around at allot of coatings and the like but I remembered how I had made my motor mounts in my car! I used a two part urethane. It's called Flexane. It's made by a company named Devcon.
Heck it was a real good urethane that could be brushed on or even used to dip things in. So I decided to give it a try.
I bought 2 of the kits and mixed about ½ of the first kit up and gave all the coils a good coat, making sure not to get it on the plug area or the side that connects to the spark plugs. I took off the rubber boot on the bottom and used some plastic plugs to make sure I didn't get any in the hole. I also didn't coat where the electrical connection plugs into the coil. Make sure you don't put any under where the plug will go also. I did this and ended up having to cut off the urethane so that the electrical plug would snap all the way onto the coils. I hung them up using some wire to let them dry for about 4 hours or so. I mixed another ½ batch of the Flexane up and gave them all another good coat. I let them set another 4 hours and repeated the step again. I let them set overnight and gave them one more good coat. Now you don't want to get too carried away. This stuff builds up fast. If you put too much on you'll not be able to get the coils back in their retainer! I let them set over night again.
I put them back on the car the next day and ran the car HARD! It ran great! I pulled the plugs back out and re-gaped them to 1mm and drove the car again. I put about 50 miles of hard driving on them and they worked GREAT!! Not miss firing or spitting at all! I got the car back on the dyno and it ran great. I've put over 600 miles on the car so far and have not had the slightest problem out of it! I was also considering going with the wasted spark set up but this has worked great so far!! Here is a picture of the coils coated before I put them in the car!