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Blaise, Looks like you had quite the challenge with that first case saver! Glad it worked out eventually (with the help of the extractor). John

Yes, I did. I am now done with 4....putting in a little time here and there.

What I am finding is that my troubles are basically all related to the very poor outer thread machining on the case savers. For them to work, I have to spend a considerable amount of time cleaning them up. If not, they bind part ways in.

I just ordered another set from another vendor and will compare.

I will report back with my findings.

The block drilling and taping was....no big deal.

I have done this on several motors and each time I used TimeSerts and found them consistent, strong, and easy to manage. You may want to consider them. They are popular with VW and Porche machinists/mechanics.

I could write a book on this as it was my "punishment" at DELCO in the lab.
In short:
Torque to yield (break the item) are always far above the issued torque for production or you to use. Commonly 100-200% - I won't get into the math and it is different for some cases and gets really crazy after a while. BMW certainly did the same, likely with some variation...

A properly sized torque wrench that is calibrated or at least checked against some sort of GOOD standard is a must, using a half inch drive 200 ft. lb. wrench is less accurate than your "un-calibrated hands" for this application.

For critical stuff in the very low torque range (all that comes to mind on these bikes is the spark advance, which as Duane says, so it won't fall of... ) if an extension is used, it must be calculated for, the torque you should read or achieve will be less. (Meaning the extension INCREASES the torque you apply...) Google for the math, can be done in one's head... You are likely to see the simple math for off-sets too, keep that in mind (crow's foot wrench end for a ratchet anyone???)

I won't go into the hot-cold thing. I need not a war... I have the answers if anyone is that interested... Enjoy!

In 2000 I served a short time in a Ford Explorer assembly plant in Louisville, KY. That really was a learning experience. Ford has a team that is always going through the assembly line and checking torque operations and equipment. They never stop, if the plant is turning out cars, they are working.

I didn't get to spend as much time as I wished, but I was able to glean some new to me info from them. I would have loved to spend hours asking questions and then follow them for a full day.

Instead, they just gave me some meds. I am full of stories.

Hah, I am lucky, I got it from both ends... Engineering, bitching about the "dumb union guys screwing our product(s)" and then being the "dumb union guy" keeping other dumb union guys from screwing up. I also later worked assembly and did the on line Quality work. Yes, it never stops... Today, they use torque/angle guns for everything, funny we used gosh, 80 year old hand technology to provide the specs for totally different equipment - and GM wonders why they have "issues..." LOL

BTW, their "meds" were the end of my career there, and well, I was no longer able to be a value added asset, just a number; that is when you know it is time to move on...