I could not send it to the UK with the leaking crankcases.. would not be possible for anyone else to run it..had to have a better solution.
Water in cylinder two is dodgy as it can fill the combustion chamber.. turn it over and not compress and bend the connecting rod..now a good look with no parts!
Also the O rings on the base gasket area were broken and not sealing due to age.. (Nice detail in that area btw.. o ring on the crankcase.. then shims to set the deck height then o rings on the cylinder.. nice..)
The main issue is around the water galleries feeding up into and around the exhaust port.. all corroded and no groove left to support the o rings.
A bit of noodling with my fitter and turner mate Tjebbe!...we have done many crazy project together all over the world!
A very good CNC machinist who I worked with on the BSL500 project was prepared to have a go... machine the cases.. and make new inserts to hold the O Rings. Critical to get the depth right..and voila!
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Did this on all three cylinder bases on the crankcase.
While we were at it had them machine up an o ring mold.. so we could make new O rings for the base gasket..
Then mold the O Rings
Back together...again...
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