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OK, well, working on another case, I did the oil pickup mod again, this time with pictures. Having a lathe I was able to do a much more accurate job, and make the extension as short as possible to make getting the pickup back in easier.

Removing the rear passage plug with a dent-puller first, it was actually very easy to knock the pickup tube out that way with a long socket as a driver.



I used copper pipe again, because it is just the right size, and solders easily to the steel pickup with lead solder. Running a 5/8" drill into the end of the pickup tube enlarges it perfectly to receive a stub of 1/2" copper pipe.

I soldered a coupling over a short piece of pipe about 7/8"long. There should be 10mm of pipe exposed to go into the end of the pickup tube.
The rest was just cut on the lathe, using a 5/64" parting tool to cut the o-ring groove.

I used a leftover AC o-ring, and turned the groove until the o-ring when fitted was only .020-.025" larger in diameter than the extension. It can't be too fat or you can't make it fit into the pickup galley. The o-ring I used stretched some to fit the extension, so it got thinner.

You want to chamfer the edge of the pickup tube hole in the case so it doesn't cut the o-ring when you insert the tube. The o-ring will seat just past the overpressure return port. I tested it and it's airtight.

Then I just drilled a 5/16" hole right thru the overpressure galley:


The lathe isn't necessary, though. You can easily do this mod by soldering bits of pipe together, like I did the first time.

Very nice!
I'll have to acquire a 5/8" bit or reamer for the next one, even with the diamond sandpaper it blew chunks to fit by hand.

I had std lead solder (both plumbing type and electronics 60/40) break on some test fit installs.
(Mine is a lot longer, so harder to get the angle right)

Ended up having to buy some Silver solder.
(98% tin/2% silver) comes with a little tube of hydrochloric acid flux that won't reseal...
That seems ~bullet proof.

I used a Viton oring, stretch to fit..

I just picked the o-ring I had that would work best. The difference in diameter between the OD of a 1/2" plumbing coupling and the ID of the pickup galley is very little, and even with two thicknesses of copper to mill a groove into, there isn't much meat below the groove, so I picked the thinnest two o-rings I had, and used the smaller diameter one so it would be even thinner when stretched. Then I machined the groove and test fit the o-ring while still in the lathe until I got the rubber OD I wanted, just a bit larger than the galley ID.

Silver solder might be best, I didn't have any. I find when soldering anything besides copper, the lead-free solders for plumbing don't work well, but leaded solder seems to flow better with dissimilar materials.

The first time I did it I had to enlarge the pickup tube by hand. Since then I have a set of Silver and Deming bits from Harbor Freight. Finally some large twist drills, I've needed them for years. So the 5/8" is perfect to ream the tube for 1/2" pipe.

I was thinking of using a sealant (rheinzosil) to join the pickup tube to the copper extension to prevent the possibility of breaking the seal between the two if I were to solder them together. Any downsides to using sealant instead of solder?

It would probably be best to find something that is actually a light press fit (and a matching reamer) and doesn't need an oring to seal.

i just milled a bit of the case where the pickup tube enters so that the tube sits deeper in the case thus blocking the re circulation path.
re-weld the mounting bracket and put the pick up point lower in the case for giggles. also i think its better to dump the oil to the main case part instead of both the cam gear and the crank case itself.
by drilling the square gallary only to the main part. all the oil that gets thrown onto the cam gear is going to get flung onto the catcher thing underneath the breather tower. thus more froth to deal with.
small things sometimes help loads...

Putting the pickup in a lower area of the sump has been suggested iirc.
It bizarrely doesn't actually sit anywhere near the lowest point of the sump.