Boxerworks.com

Hey guys...quick update.

I have rebuilt heads, new pistons, and re-bore....ready to be installed.

I made a jig to install case savers...and hope to fix the threads on the block very soon. I am a bit nervous about it.

How does one keep metal shavings out of the engine? Those two forward holes go right through!

wax or grease on the drill bit will help

Well, my first take ended with a half in case saver that is stuck...damn.

http://picasaweb.google.com/blaisedesco ... 7sKaptKfQA

The drilling went well. The tapping went well. But the case saver insertion did not.

Anyone with some case saver experience that can give me some pointers? Run the tap in a few more times? Clean up the case saver? Make a beefier insertion tool?

I will work on getting out the messed up case saver tomorrow. I will probably weld a bolt to it.

Here is a little write up that I found....

http://bobhooversblog.blogspot.com/2006 ... avers.html

This guy writes:

"To thread the case savers into the case I modified a couple of old spark plugs, fitting them with 8mm and 10mm stud-ends to serve as installation tools. (If no one is watching, I run them in with an air tool.)"

Does the spark plug tool make any sense to you guys? I like the idea of using an air wrench:)

In my googling on the topic....I don't see much about inserting them...so figure that they usually go in easy.

Using an air wrench allows one to more powerfully get in deeper trouble. By hand, most people will stop when they get into a situation where things are going south.

Cases are not hard to find, but only one has the correct VIN and that means that I move very carefully.

I did a little more homework and found that the case savers are not consistent. Some of them screw into my test hole easily, some easily halfway...and some bind right away. I was dump enough to force one that did not go well.

This would be easy with the right case saver.

Now back to cleaning up my mess.

Kurt in S.A. wrote:I really find that hard to believe. Why then did BMW limit the torque to 29-31 which I think was the highest for some years. If they can take double that, whey didn't they provide a range of say 30 to 40 and say that was good? Maybe we're talking apples-oranges. If 25 is good enough, why go any higher?? It just doesn't make sense.

I call that "margin of safety" and 50% is a number I can believe with no doubt in my mind.

When the aluminum cylinders heat up and try to get longer, the clamping pressure goes a lot higher than provided by 26 to 29 ft lb of torque at "room temp".

I got the jammed insert out.

Lesson learned....test fit the inserts before using them....and don't force it:)

I am adding photos to my album as I progress if one is interested.

I'm following with interest, Frog. Sympathies attached for the difficulties, but you seem to be on top of it. I like your drilling jig.