about to start my first rebuild this weekend hopefully.

just checking all the parts and have a ?

is the releaf groove for the cylinder base O ring in the cases or the cylinder?

Was cleaning the bores today and noticed there was no releaf on the base of the cylinder so not sure if it in the cylinder or if there was a cange at some year point.

Nothing on the cylinders from memory

thanks Ando, I have only found 1 other mention of it and suggests it is in the case's. No pick of cylinders from the bottom.
don't bother me either way but if it is meant to be in the cylinders I need a gasket before I pull it to bits.
I think I am good to go.

dyno yes twin cam. no problems putting it together.
the cylinders on the bench do not have a relief for the o rings. I expected they would although I don't know why I thought that.
Just want to be organized so I can pull it down and rebuild with out chasing things up, have had enough delays with parts and machine work.

pulled it down tonight, yep as said the relief is in the case.

One thing I did notice it is a real bitch to get the manifold bolts out and I can imagine a bigger bitch to get them back in and torqued up.
Any tips or tricks

I use WD40 on the manifold rubbers so they can slide when lining up. Ozroder taught me a good trick by leaving the heads un-torqued until the manifold is in and bolted lightly but not torqued. Both heads will rock on the dowls to help get the manifold square between both heads. Take your time and spend the extra time port matching the manifold to the inlet ports on the heads. I would also check how far the slugs are down in the hole at TDC before chosing your head gasket thickness.
Good Luck

Hogbag it was me that told you about the intake bolts over the phone a few years back

and to have two allen keys one that is cut down for the flange bolts on the LHS and a long allen key with the ball on the long side for the RHS

Ando you are corect and where very helpfull when I was cutting the valve pockets with a demel for my larger inlet valves. As we know its best to get everything right the first time around as I built my motor 3 times before I was happy with the compression for the wood 5-6 cams.
Cheers

Ando
I brought a S&S 52mm throttle body but have not got around to fitting it. I'm riding to work these days and most weekends are taken up with home duties so no time to get the bike on the table. The bikes getting a bit noisy in the top end and my stock componsator is just about toasted. Hoban bros is bringing out a  new direct drive componsator in june. I will strip the bike down for a couple weeks and fit the 52mm body and hopfully  tune with a new  mastertune2 money permiting. Still very happy at 103 with the wood 5-6 sticks so no need to go bigger at this stage.

patience you say not my strong suit but will comply this time. no real rush, pissing down every day up here, pick up heads Monday and drop off the pipes for 02 bungs

HogBag front .002" rear .0025, couldn't get my dial stand positioned for the crank, no gear drives so I don't really want to know

wd 40 sounds like a smart way to go. need all the luck I can get with my fucked up hands.

O rings are all on cylinders

Ozymax
What head gaskets are you going to run mate.

.030

Sounds great she should kick arse when its back tojether.

Ive been seaching and found your old post regarding your heads with 1.9 inlet valves. What pistons are you going with Ozy ? Are you planing on claying the valve to piston clearance. Whats the rest of the build cams,pipe, throttle body etc

I was trying to change the valves to get the cc down, the heads were supposed to come at 79cc but were 84 and 85.
I put it together and checked all the clearances and had heaps of room. So the heads are off getting .040" removed. I will volume them when I get them back and match them up
Pistons are CP Carrillo flat tops. looking for 10.7+ :1
cams are woods TW777
50mm SE Throttle body not sure if it will be enough, I matched up the ports, Pipes are the originals with cat gone and the flapper valve section replaced. Baffles are made by Pipe Master here in Bris, not sure about the sound or the flow but time will tell.
SS stealth A/C
Bandit clutch with Muller ball and ramp

107. It may need more than the 50mm but going to 58 to find 4-5 hp up top not really what I want. "At the moment"

See how it rides and go from there
hopefully get it on the road end of the week

I thought the same thing and checked on big boyz site and came up with 10.8 static 9.8 corected at 208 ccp with the flat top CP's and intake at 42. She's gunna rip with a good tune but you might need a couple jagg coolers if you get any detonation in the qld heat.

http://www.youtube.com/watch?v=bh3Kwn9tFvc

got the harley cooler on it but will monitor the temps. may need more, thinking or running 2 on it and just plumb them together. Will definitely need a descent tune to make it work.
spoke to Bob Woods and his advice for that cam was from stock to 11.5 so at 10'8 that's about the middle and I can go the next cam up if it doesn't work out with that compression.
I've also geared it down a little so that should help it spin up a little quicker
big boys site has it around 10.7 depending on what the head cc ends up. I can always open it up a little if needed. Not sure that cutting .040 is actually 6 cc due to the shape but it is some where near it.
don't really want to use the .040" HG as that will change the squish significantly.
there will be no sharp edges in the chambers and I will be cutting in Singh grooves when I get the heads back.
should get away with the manifold with .040" cut but will check it and narrow it up if needed. Not the easiest to get at with the seals but I made a pattern to infill with bearing blue to check it.

any way only time will tell if it's any good and it's just more money and time if it don't work out.

Bob wood knows his shit and wont steer you wrong. I'm running his specs on his cam with 103 CP slugs + deck height 002-004 with .034 james gaskets 10.1 195ccp jagg cooler 50mm bassani 2-1 vpc tts vtune etc and very happy.

http://www.youtube.com/watch?v=bh3Kwn9tFvc

I would say that a 42 intake closeing and 10.7 is a bit high and will need a really precise tune BUT Bobby Woods does know his shit and if says it will work then it will work

I think ya gonna be happy as when ya get it running