Head Studs Bottoming in Case Savers. What to do?
 

I'm installing my stock steel head studs (from the 2.2 donor) in my 7R case with newly installed case savers. The studs are bottoming in the case savers while still standing 140mm in length. It is obviously the case saver that is stopping progress, as the hole the case saver is in is clearly deep enough to accommodate the stud. Should I use a tap to remove the obstructions? Why do the threads not allow a stud to pass? I tried several holes with the same results. The case is sealed, so I'm also concerned about any metal shavings that might go in unwanted places.
Thanks,
-Scott

Use a 10 mm thread chaser. It is different from a tap in that it is not designed to remove material.
You can get one from any company that sell TimeSerts.

Thanks, Henry. I'll do just that.
-Scott

Case Savers
 

Hey Scott, did you install those case savers yourself?? where did you get them etc etc?
thanks
Brett

Brett-
They were installed by a Porsche-only machine shop. The shop provided and installed the case savers.
-Scott

They should have checked the threads and chased them if necessary. The case savers are deformed upon installation, and often cause binding on the head studs.

-Wayne

Wayne-
I was surprised that the threads needed to be addressed. The Southern California shop in question has a very strong reputation. As I could not locate a thread chaser, I made one from a bolt by grinding two channels along the length of the shaft through the threads. This tool did a good job of reforming the threads without removing much material. After cleaning up the threads I knew I needed to make sure I got any remaining debris out of the sockets the case savers sit within. Out came the q-tips, and I found tons of magnesium flakes left over from the installation. I used about 100 q-tips to clean the 24 holes. I'm not exaggerating. I think it took about two hours. The book says it, and I have found it to be true multiple times already: assume nothing, measure everything. It doesn't mater who does the work.
-Scott