First let me say that while I am a HD mechanic, most of my engine expereince has been with twin cams but I`ve done a few 80" top ends and cam swaps. Ok, soI got this 96" evo project in my garage. It was suppost to be a simple install the top end and cam and get the motor ready to go in the frame. Well this is my first big bore evo andI didn`t realize some of the special clearances needed. These are S&S 3 5/8" sidewider cylinders on stock cases. I`m all set to put the barrels and pistons on and I notice the hole in the base gasket for the oil drain doesn`t line up. soI dig out the instructions that came with the kit and it says to chamfer the oil hole on the side that doesn`t line up. so whats the best way to do this without getting metal shavings in the crank cases? I need to get this thing together for the guy not to mention it`s become such a pain in the ass that I want it gone but I won`t half ass it just to get it out of here. i need to get it done right so it doesn`t come back to bite me later. Thanks guys.

You have a conundrum.There are all kinds of ways to do it BUT no guarantees you will keep all the crap out.Maybe a plug of somekind bathed in grease that you will be able to pull out when done.You know the best way to do it.Good Luck.

__________________
2002 RK 124" S&S Evo
2006 RK 155" R&R TwinCam

Yeah I just didn`t want to split the cases again. I already had to do it when we fixed the cylinder stud threads.

Maybe tip the engine so you are work "uphill" with a vacuum cleaner sucking next to where you are chamfering.

That is pretty much whatI planned to do after talking to a couple people at work. I think this would be the best way and i won`t have to split the cases. thanks

Can you chamfer the jugs instead of the cases?

__________________
Rob85wg,

Let's roll...............................

They are S&amp\\;S barrels for big bore and they are the reason I have to chamfer the cases. I`m going to go slow and just take enough matieral to line them up.