Did some more work on the engine rebuild today. The new case was machined for 94mm bore and & clearanced for 86mm stroke by Scott at Hummel engines, just like the old case. However, I have a massive Mosler Hercules crankshaft which is probably a bit bigger than what Scott installs in his standard 2400cc engines as the clearancing on the new case wasn't enough to allow free rotation of the crank. Thus I had to clearance it myself a bit further. This is easily done with a Dremel tool. I used the old case as a reference to make sure I did not overdo it. I had to work on the top of the case, one of the case savers and cut the notch on the cylinder bore a bit further. I test assembled the case in the end and the crank rotates freely now.
Another thing I discovered is that the old case was modified to allow for a split #3 main bearing. Requires an extra hole for a dowel pin in the right side of the case. I now have 2 options, either rebuild the crankshaft and put a standard #3 bearing on or modify my new case to allow for the split #3 bearing as well. I think the latter will be easiest. the way this is done is by using a spare #2 bearing with the hole for the dowel pin drilled trough as a drill guide. I don't have a spare #2 bearing so I can't do this one for now, I'll go see my VW friend tomorrow to see if he can help me out.
