Case inspection prior to rebuild Options

[Cevan]

What is the normal practice in terms of inspecting the case halves prior to a rebuild? Is this something I can do myself?

All the bearing surfaces looked fine and the connecting rod play was between .008 and .010. Assuming I don't see any visual signs of damage, does it need to be sent to a professional who I assume has an expensive tool that checks the alignbore?

[HAM Inc]

Couple of questions: Do I have to remove the head studs in order for a shop to check the deck registers? Is heat usually required to remove the head studs?

Yes, the studs should come out. Use heat if you have to and the penetrating oil of your choice.

When you reinstall them, what keeps them from going all the way into the case as most of them are visible from the inside of the case?

Just screw them in till the last thread enters the case, they'll stay put! You'll probably have to apply oil to the threads just to get them to screw in. Loctite them if they are loose.

After almost 4 decades of use most cases require some intervention. Recognizing what needs to be done is primary.. Actually doing it is secondary.

Jake is spot on with that observation! These old aircooled engines are great when restored properly, but they do require a good deal of very specific prep work before final assembly can even be dreamed about!
And from what Jake has been telling me lately damn near every new replacement part from bearings to oil pumps to distributors are getting harder to source in quality, ready to install condition. The older these engines get the more of a challenge they are to build properly!