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[CVO2FIXUP]

 The space, freshly cleaned up.

[Lars]

This is going to be a very interesting build to watch. Hope it turns out to be the build you want it to be. You're doing a great job of posting the progress. That's a really nice space you have to work in as well. Good Luck, and keep us posted.

[CVO2FIXUP]

Made a horrible discovery today. This can set the build back a bit. Will be checking with a pro welding shop today to see if they can weld up a cast alluminum case.

[CVO2FIXUP]

The problem!

[2 ROSE]

Hmmm...is that a crack I see???

[smkymtnboy]

The problem!

rebuild a couple wrecked bikes. that cracked case has always been my biggest fear. not the end of the world, but I am sure you felt that way when you found the crack

[phato1]

You probably already thought of this but....

[CVO2FIXUP]

 All these options are on the table as we speak. Once it is all taken apart will have a better idea on how to proceed.  Will try like hell to save the cases. New cases are $3000 and a six week wait. We would have to give the original cases back to HD before they will order the new ones.  I hope we don't have to go that rout.  Good idea to install a remote oil filter assembly. Will explore this as a last resort.  Will know more in a few days.  Cheers.

[CVO2FIXUP]

 Oops, something happened. While transporting the engine to the weld shoppe the owner some how snapped off the cracked filter base clean off the case. So we are going with what was suggested here earlier. Call it plan B.

[phato1]

Looks like "plan B" should work, enabling you to save the expense of, and the wait for, new cases.

[CVO2FIXUP]

Plan B, which will look something like this will be done much neater. With better lines and nicer routing.

[Ridgerunr]

That should work very well.
Check out this guy, stand up man, great customer service. http://www.mooresensible.com/

[cmashark]

Plan B, which will look something like this will be done much neater. With better lines and nicer routing.

I like that. Who makes it?  Wonder if it will work with vented lowers.

[2 ROSE]

Ok...what has happened here. First I must apologize for my ignorance. As I stated in a different topic, my extent of "wrenching" entails installing a new mirror after not fully engaging the kick stand...I turned away from the bike took one step and heard the most god-awful sound there could be to a rider. I must say though the mirror I installed is still attached.
So if someone could walk me through the difference between plan A and plan B, in a not to technical manner it would be deeply appreciated. Be advised though you would be explaining to someone who would be challenged to tell where the engine stops and the tranny begins.
I think it will be really interesting to follow the process of the build. And maybe the pros and cons of each plan.
If what I am asking makes me out to be too much of a pain in the ass and not worth the trouble thats fine, I will still follow the build.
Thanks for you guys help and patience.
john

[BakedInMN]

I'll break it down Barney style as best I can:

The location where the oil filter mounts has a crack (for this explanation I'll call it the oil filter mount but that is not 100% accurate). The cast piece on the engine is where the oil passages go from/to the engine/filter. The crack (guessing without being able to see the actual engine) may have been large enough to penetrate the oil passages, and weaken the casted mount point (consider it being a part of the engine case).

Plan A - repair the crack by welding. Tricky with cast aluminum (but I'm no welder), and it may not solve the issue (oil inlet port and oil outlet port may be no longer be physically separated by the casting if the crack extended to the oil passages). So the fix may not work.

Plan B - cutoff the mount point exposing the two oil passages (in and out). Now with the two passages exposed you can tap them and run new oil lines to the new oil filter mount. Mount the the oil filter somewhere (in the picture it is on the bottom forward part of the frame).

That is a perfectly acceptable solution. Some older bikes had the oil filter submerged in the oil tank (i.e. Shovel Head FLH), and it was common to relocate the oil filter in front of the engine on the frame.

This is a general explanation without having physically seen the engine myself. If it's way off I'm sure someone will correct me.