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[Twolanerider]

Was asked in a PM and started typing as if I knew an answer.  Then quickly realized had no clue as to specific answer.  I always just cut the cases if the cams didn't clear without worrying about any more detail than that.

So; does anyone know specifically how large of a cam can be used in Twin Cam case without having to cut the case for clearance?

The question was asked to me regarding an 04.  Just for curiosity, however, I'd be interested in both the older and newer cases.

[hogasm]

Did not have to cut 05 cases for Zippers 575's but did for S&S 570's   

Did not cut 04 cases for Kury 24g's but did for S&S 585's

Weird thing is that Portholes's 05 cases were relieved from the factory

[Twolanerider]

Did not have to cut 05 cases for Zippers 575's but did for S&S 570's   

Did not cut 04 cases for Kury 24g's but did for S&S 585's

Weird thing is that Portholes's 05 cases were relieved from the factory

That's the kind of inconsistency I remembered as well.  Though I didn't maintain detailed enough service notes on other people's bikes to have anything but the recollections.

I did have to trim for the 575s when they went in the red bike.  Barely.  But did.

Pretty sure I remember having to relieve for a set of 570 lift sticks also.  But also pretty sure I remember an engine that got 575s that had plenty of clearance. 

Wouldn't think the castings would vary.  Perhaps they don't within model years but do across their history...

If that variation is more than just my feeble memory it does at least seem that somewhere around 570-575 is the cutoff point.  That's more than I felt I knew without any other independent verification before.

[sadunbar]

I installed Zippers 575's into an 04 SEEG without any clearance issues...

[porthole]

IIRC, the S&S instructions for gear drives give the info needed regarding sizes and fly cutting.

[HD Street Performance]

does anyone know specifically how large of a cam can be used in Twin Cam case without having to cut the case for clearance?

Nope, not here
The A and B earlier motors had different case dimensions and then around 04 they opened them up I suspose so dealer wrenches could plug and play easier.
The cam lobe dimension depends on the base circle so even looking at expected gross lift is not an accurate indicator. I just put three rounds of black tape on the lobe and see if they clear, if not grind. This is a job that takes cleanliness and skill masking regardless of the tool used.

[Twolanerider]

does anyone know specifically how large of a cam can be used in Twin Cam case without having to cut the case for clearance?

Nope, not here
The A and B earlier motors had different case dimensions and then around 04 they opened them up I suspose so dealer wrenches could plug and play easier.
The cam lobe dimension depends on the base circle so even looking at expected gross lift is not an accurate indicator. I just put three rounds of black rape on the lobe and see if they clear, if not grind. This is a job that takes cleanliness and skill masking regardless of the tool used.

Your method sounds like mine Don.  If it won't fit with obvious clearance; cut and don't worry about it .