The large ORANGE screw next to the oil filter is ever so slowly leaking. It has a washer but is there anything else I can do to stop the leak. It is tough to know how tight to get it, since it is just a slot vs a bolt head that I could get a socket on and torque it. I suppose I could make a tool to go in the torque wrench.

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I would try a new gasket and put a thin line if RTV on the threads near the gasket end. This is one spot I don't think I have ever had leak on mine. I used a screwdriver socket on a 3/8" ratchet to tighten it down.

I'd replace it with one of these new ones....they have a hex instead of the slot.
http://type4store.com/products/oiling-syst...lief-screw.html

The store has a $50 minimum and wanted to ship that one part for $20... Any other alternatives ? Is there a generic screw that could work ??

Jim, here is another alternative from Aircooled.net....I forgot about Type 4 store's shipping requirements. http://vwparts.aircooled.net/Allen-Relief-...113-115-431.htm

I might buy one of the aircooled units. I emailed and asked them if theirs has the nub for the spring and if they sell washers.

I read a how-to somewhere that said to use a large screw driver like a chisel and tap the outside edge of the slot to tighten it up.

How much oil will come out if I take it off with the case full?

The large screwdriver idea does work to tighten it but it is easy to bugger the slot up.
Only a small amount of oil comes out.....when I installed my pressure block off from Tangerine, only about a teaspoon came out of mine.