Plug
 

Flebay! $15 plus shipping just can't be beat unless you make your own...but I don't know anybody who has a mill for that kinda precision work:rolleyes:

That would be hard to beat. If I made a one off like that the cost of raw materials alone would have run almost as much, lol.

Case saving measures required
 

I've got 2 iffy head stud holes in the left case that I'm going to repair with Time-serts, so progress is slowed a little. One of the holes wont hold torque even with green sleeve and the other holds with green sleeve, but if I'm gonna fix one I'll fix both while I'm there:rolleyes:

http://forums.pelicanparts.com/uploa...1310576108.jpg

Front wheel brg progress
 

The wifie asked if I'd PLEASE try not to make any banging noise in the garage early on Saturday mornings, so I decided to buy a silent banger:)

Grizzly 10 ton press...whattcha think?
http://forums.pelicanparts.com/uploa...1311042174.jpg

The press made short work outta the front race installs


http://forums.pelicanparts.com/uploa...1311042255.jpg
http://forums.pelicanparts.com/uploa...1311042275.jpg
http://forums.pelicanparts.com/uploa...1311042304.jpg

Seals are in so front ens should be done soon
http://forums.pelicanparts.com/uploa...1311042349.jpg

Good addition to the shop there Rick, one of those is on my wish list as well.

new case threads cut for time-serts
 

I finally got everything together I needed to drill & tap the case for time-serts. It took a little while to figure out how to dill & tap with precision w/o using a drill press, but I gotter done so no porcupine case hereSmileWavyhttp://forums.pelicanparts.com/uploa...1311347703.jpg
http://forums.pelicanparts.com/uploa...1311347712.jpg

Front End Finished!
 

I'd rather build a motor any day then work on 24 year old front suspension parts, but it's done now so I can get back to the motor:D http://forums.pelicanparts.com/uploa...1311612288.jpg

Don't forget that you still have the rear bushings and torsion bars to deal with, lol. ;)

Thanks a lot for the reminder...some new rear parts ordered:rolleyes:

My original plan was some slighly stiffer hollow bars for the rear to compliment the slightly larger front bars I passed on to you.

What did you get?

I'm going with a new set of Bilstein HD shocks in the rear from our gracious host, so for now I want to see what those feel like with the stock rear T-bars. I like to approach a stiffer/harsher ride in small increments. It's way too easy to go to far too fastSmileWavy

time-serts in
 

Time-serts are done, so on to building up the cam towers nextSmileWavyhttp://forums.pelicanparts.com/uploa...1311700495.jpg
http://forums.pelicanparts.com/uploa...1311700504.jpg

Before you put those jugs back on you might want to builld that base gasket area back out with some metal epoxy so it has a good sealing area.

Good eye! I was thinking the same thing, but decided it was overkill when I noticed some of the through bolts already had more material then that removed.

However, I did clean the mating surface on the case real good and added a little fresh sealant to the cylinder gaskets before dropping the jugs in the holes...nothing wrong with a little added insurance;)

That should probably do then, digital photos often make it hard to tell just how thick something is.

I'm still left pondering why those two holes were so much worse than the rest. :confused:

Don't ask cuz it was my fault. I buggered up the threads in those two holes otherwise they'd all have been fine...most were a little loose so I sured them up some with Permitex high temp green sleeve, but all in all that's one sweet case you had there...show's that even soft aluminum can be preserved if well cared forSmileWavy

New rear brake lines
 

Starting on the rear end now. Replaced the old rubber flex hoses with SS lines same as front along with new lines to the calipers. Man it's hot in the garage right now!http://forums.pelicanparts.com/uploa...1311903938.jpg

If that garage has a window you could always put a A/C unit in it. The one I have keeps the garage pretty cool when its on with the doors closed.

Two windows! However, a window shaker unit would be frowned upon by the home owners association so I have a box fan I put in the window to circulate the hot swampy air:p

Well that sucks, too bad those stand alone units with a duct to carry away the hot air are so expensive since that would be an option as well.

Congrats on ticking over the 10,000 view mark Rick. Only the Dude's 911T thread is ahead of you now, lol. ;)