OK, I got it!! No laughing though but it's almost all back together again. It is an OS .91FS so no, I couldn't cut slots. Don, some of my older ellen wrenches are really short!!! I never buy new ones, I have a tool box full of them.
I just kept sticking the engine in boiling water then pulle it out and used a punch with a big hammer and gave the screws a heavy rap then stuck the engine in the freezer. I did that several times then all of a sudden they came out.
Now for the bearings!! The front one came right out with a little help from a wooden dowel and a hammer, the rear one was really stuck and not even going to pop. Back to the boiling water and some whacking, no way. Boiled it for a very long time, pulled out a round flat bottem punch and really gave it a smack. My, how easy they slip out with the correct tool.
The bearings were packed with nasty old Castor and pretty scored, you could hear the grinding when I flew the plane. I have pulled out bearings that were a lot worse then these, at least these wree still in the races.
Had the engine about half together when I discovered I had forgot to install the lifters!! No the head screws wouldn't come out again?? I took an old easy out and ground it down to fit then they came right out. I went ahead and replaced the head screws at that point.
Engine is almost all back together but I got tired of fooling with it last night, .
I think it was Aeros idea about heating and using the freezer, that seemed to do the trick.
Don, the wrench I was using was getting a little short from grinding so I went into my box and found a nice new one and did your tap in with a hammer trick, it seated it very well and held on so I could get them to unscrew. Why I didn't replace them all before I tried to reassemble?? Sometimes I just do some stupid things to try to save a buck.
Thanks to all of the guys for the input, trust me, I tried them all. That set of screw removers sold at Sears worked pretty well from what I have been told but you have to buy the complete set and I seem to have ran out of money so I'm working on the cheap right now. I had a set like that years ago but they got up and walked out of my tool box??
Thanks guys, everyone was a big help and maybe some of the new guys learned something. Even old hands at engine building get there mules kicked once in a while. This one fought me but I won the battel in the end!!
Gene