This 94mm case had problems with the deck surface. At home machining got it fixed

[@musoangelo]

I'm hoping you did some investigation on those case savers. A half century ago I had a friend who had a bus engine and his engine had been apart for months. We wanted to go to Ensenada for the weekend and another friend and I offered to put the cylinders and heads and get it running again and we had a good weekend but the engine leaked oil. It was coming out of the case savers which had been installed by someone else and didn't have any sealant on the outside threads. That engine leaked oil for quite some time before someone actually figured out where it was coming from.

[@amazeddude1780]

I din't see the original set-up, but is that case casting level? It looks to me like it is sloping away from the cylinders, which would explain why the mill cut into the casting around the first insert as you had zeroed the Z axis on a spot further away on the Y axis from the cylinder bore.

[@leftlanewilson]

We didn't show the set up in this video. The fixture that we use to hold the block is trammed in with the mill. By sitting the case half on the fixture is how we square everything from the crank centerline. The reason for some of the inserts being cut and others not is because the inserts were not installed at equal heights, or the casting of the block was lower/higher in some spots. This can also be seen when cutting for the cylinder, the cutter hits in some spots before others because of the original casting. It would take between .020-.035 thousands before a clean cut would start.

[@amazeddude1780]

@ Thanks for the reply! I understand the case mating surfaces mounted against the table should be good, but perhaps it was an illusion, but the casting does not seem to be parallel to the case parting plane. Maybe it is just casting irregularities as you say, so I suppose you used the blueprint specifications

[@leftlanewilson]

It very well could look like that because of the lighting and camera angles, but everything was true