You may be right that the case is to pounded New cases are availible with
fuel pump openings

align boring is doable to .060ths with a 2.mm thrust the extrthicknesss of
the thrust is on the flywheel side. When I thrust cut a case I trim the
inside to make the inner thrust surface is flat then I can measure from that
flat surface and make the cut on the outter thrust surface.

I dont think align boring is a compromise at any size if its done right but
the case can be so distorted that the cam will bind as the block heats up.
For this reason I have a cam bore tool that trues the center cam bore

so what does he do for a fuel pump

Bob Donalds
Bodton Engine

----- Original Message -----
From: "Mike S" <mikes@FLATSURFACE.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Friday, January 18, 2008 6:30 PM
Subject: Re: NVC: Type 1 case

> I'm in Michigan.
>
> The saddles are 65 mm dia, which I think is stock. He didn't bring the
> crank home, but said it looks good. #1 bearing saddle is pounded, and
> would probably be fine with a 0.5 oversize. The problem is the thrust
> surface (and dowel pin hole) are really bad - the flywheel side of the
> thrust surface is pounded in about 1.65 mm. I think thrust cuts only go
> to 2.0 oversize, and must be centered (1 mm per side), so it's not
> doable without welding (if that is even possible or desirable).
>
> It's a AJ case (AS21 - fuel injected, no fuel pump hole) case, so
> finding one of those would be ideal. I was mistaken, it's a '75, not a
> '74.
>
> He may just end up having to get a new case (and a fuel pump block
> off).
>
> He bought this knowing there were engine problems - lots of endplay.
> He's rebuilding it as a high school auto class semester project.
>
>
> At 05:53 PM 1/18/2008, Mike wrote...
>>Have you had it checked by a competent, experienced aircooled VW
>>machinist?
>>It may be fixable, depending on the current oversize, thrust area,
>>total depth of the damaged areas of the bearing saddle, etc.  Even the
>>destroyed dowel pin and hole is repairable.  There are many other
>>areas that need to be inspected for case reconditioning, also, to
>>determine if it's doable or junk.
>>  I have some cases here in MA, where are you?
>>
>>Mike B.
>>
>>----- Original Message ----- From: "Mike S" <mikes@FLATSURFACE.COM>
>>To: <vanagon@GERRY.VANAGON.COM>
>>Sent: Friday, January 18, 2008 4:54 PM
>>Subject: NVC: Type 1 case
>>
>>
>>>I'm asking for my son, who recently bought and is restoring a '74
>>>Beetle. His #1 bearing spun.
>>>
>>>Anyone have a decent AS21 or fuel injection (late AS41) Type 1 case
>>>for
>>>sale, relatively cheap?