If you get the cases rewelded and want to smooth out the weld where the case mounts against frame, there's a poor-man's way of acting like a machinist...
I trimmed the case mounts on a project bike of mine and wanted to "machine" the bosses on the cases smooth where they will rest inside of the frame. I took an engine bolt, washer/spacer, die grinder sandpaper with a sticky side, double-sided tape, and a hand drill and...
1) Cut the sandpaper to the ID and OD of the washer/spacer
2) Put a piece of tape on the other side of the washer/spacer and cut the tape for the hole.
3) Slide this over the bolt so the tape will attach to the bolt head
4) Slide the assembly through the engine with the sandpaper against the surface you want to smooth out.
5) Attach the drill to the threaded side of the bolt
6) Spin and apply slight force
I never updated the page for my project, but here is some text and some pictures of the procedure (scroll down to the June 26, 2008 post)...
http://www.desmodemon.com/mega_paso/engine.html
Desmo Demon,
Terry
Original Post -
"Remove the engine, get it to a welder, get it fixed and get on with it! Break that chunk out with some authority and have it built back up and file it flat."
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