cylinder head studs

[Sonerai13]

What sealer would you recommend for the threads?

I've never put any sealer on them and it's never been a problem. If you really feel that you can't live without it, just use a very light amount of fuel lube (usually marketed these days as "EZ Turn") and that wouldn't hurt anything. But it's not necessary.

I am still unconvinced that the inside of the case halves were not cut too deep during machining thereby cutting off the inside end of the inserts which are normally blind as they are in in automotive use.

Your description sounds exactly like the cases we ship every day. Send an email to tech@aeroconversions.com so I can get your email address at work and I'll send you some photos of the case machining. I'm sure you'll see that yours looks exactly like what my photos will show.

I am surprised that other builders have not brought this subject forward before now.

That's because it's not an issue. Build the engine like we show in the manual (and i show in the video) and it will be a good engine. Seriously.

[surfly]

I believe that I have not made myself perfectly clear. My only problem is that my case halves came with inserts that ARE NOT blind. Looking into all of them it is a clear open thread all the way from the outside to the inside of the case halves. I believe that the inner part of the inserts were completely ground off during machining leaving them completely open.

How many other case halves were machined this way leaving the inserts completely open from the interior to the exterior of case halve? Is this normal?
Surfly

[Sonex1517]

Surfly

I think contacting tech support as suggested, with clear photos of your case is probably the way to go. Posting here is a great way for community involvement and discussion, but only the factory can accurately answer the question. Joe cannot do that here, especially without a photo.


Robbie Culver
Sonex 1517
Chicagoland

[rizzz]

I believe that I have not made myself perfectly clear. My only problem is that my case halves came with inserts that ARE NOT blind. Looking into all of them it is a clear open thread all the way from the outside to the inside of the case halves. I believe that the inner part of the inserts were completely ground off during machining leaving them completely open.

How many other case halves were machined this way leaving the inserts completely open from the interior to the exterior of case halve? Is this normal?
Surfly

My case came from great plains and from memory I believe it was exactly like that as well, so was my previous hummel case I think, I still have that one, I'll have a look but I think that's just the way they are.

[Rynoth]

I believe that I have not made myself perfectly clear. My only problem is that my case halves came with inserts that ARE NOT blind. Looking into all of them it is a clear open thread all the way from the outside to the inside of the case halves. I believe that the inner part of the inserts were completely ground off during machining leaving them completely open.

How many other case halves were machined this way leaving the inserts completely open from the interior to the exterior of case halve? Is this normal?
Surfly

You've made yourself clear (at least to me), my case was like this as well (backside of the inserts are machined.) Didn't use any sealant, so far no leaks from the studs. Yes, it's normal.

[Gripdana]

My case is exactly as you describe. I built my Aerovee per the manual and video. My engine has over 60 hours. Joe Noris (Sonerai13) from Sonex commented above. If you have any doubt please contact Sonex tech support with photos. I think your case is normal. I do not have any leaks from the cylinder head studs. They are flush on the inside.

[rizzz]

Just to put your mind at ease, have a look at this thread on the TheSamba forum (the biggest VW forum out there):
http://www.thesamba.com/vw/forum/viewto ... ?p=5578697

Some great close-up pictures of a machined VW type 1 case. This particular case has some additional features you won't find on your AeroVee but I believe the "inserts" (also known as "case savers") are exactly as you describe, also partially machined away on the inside so you can see through them.

[rizzz]

and this one which I found elsewhere on the net shows a bit of both, the case savers have been machined along with the case but only the 2 on the left have been machined so far the case saver opened up and exposed the threads:
http://statesidetuning.com/special/94mmcase3.JPG

I guess it's just a matter of how far they were installed before machining the case, in any case, this proves it should not matter.

[surfly]

Rizz, thank you for that website.
After much study I have resigned myself to accept what Sonarai13 had suggested earlier on this subject matter in that I am overthinking this and proceeding on with my build. I want to thank everyone who posted concerning this.
Surfly

[surfly]

Rynoth,
I can very easily turn all of my head studs through the case savers on into the inside of the case halves just using my fingers. I just placed a finger inside the case half to feel when the stud was at or near the end of the thread. I will also use the same Permatex that was used to seal the case halves to seal the stud threads. A note on Permatex is that it takes only a very thin application to get excellent results.