G/B Outer cover won't fit

I am assembling a gearbox for one of my projects, when I went to fit the outer cover it wouldn't fit flush with the inner cover. I began to remove the parts that attach to the outer cover to see where there was interference. I got to the point where the outer cover was stripped and should have just popped on the inner cover, but no dice.

I found that the outer cover was hitting the K/S spring before seating. The G/B shell has a number that matches the number on the head stock which shows that the machine was produced as a '72 Combat, the engine number is from a '73, 750; I guessed that the original Combat 750 had blown up and some ambitious PO had put a '73 750 in its place.

Anyway: I checked the part numbers for the:

Outer cover '71 to 73-74: 06-0740
Outer cover K/S steel bush 71 to 73-74: 04-0472
K/S shaft '71 to '73-74 04-0472
Inner cover '71 to 73-74 04-0467
G/B shell '71 to '72 06-0808
G/B shell 73-74 06-4126**** The only difference, but potentially irrelevant

I have the original outer cover that came with the my machine ('72 beat to crap) with the outer cover of a complete G/B that I purchase on E-bay (71 to 74), the one I'm trying to fit, and noticed that the boss that fits against the K/S spring was deeper then the original outer cover by about .125" The original '72 cover will fit and seal, but it has dings and gouges that wouldn't polish or sand out without tons of elbow grease that I no longer have in me.

I am baffled that I can't make the outer cover seal. Anyone run into this? It doesn't seem to add up, but there it is. Your words of wisdom are appreciated.

Bill.

RoadScholar said:

Outer cover K/S steel bush 71 to 73-74: 04-0472
K/S shaft '71 to '73-74 04-0472

Click to expand...

K/S shaft is 04-0477

RoadScholar said:

the outer cover of a complete G/B that I purchase on E-bay (71 to 74), the one I'm trying to fit, and noticed that the boss that fits against the K/S spring was deeper than the original outer cover by about .125"

Click to expand...

Could be a pre-'62/'63'/64(?) outer cover, in which case, other parts might be pre-'62/'63/'64 (inner cover, K/S spring) if the outer cover fits that box?

I found the shell that provided the outer cover that isn't fitting with a 126471 number indicating a '68 Atlas, possibly a P-11, original fitment. So I have a G/B with a matching shell and inner cover and a 207397 number.

I will either have to machine down the K/S bore in the outer cover or purchase a different outer cover; I wish there was an easier way...