I’m sure this is something you’ve already done, but would it be potentially a decent idea to call a prominent ROK builder in the USA? Any of them likely would have torn down the GP new or old versions so many times they know the differences in their sleep.
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I’m really tempted to tap a hole in the cover. I don’t know how it would work with the ignition pickup in the way. Going in from the bottom could be a better solution but then there may be an issue with the motor mount.
I was always tempted to cut the gasket and allow the lower chamber (where the water pump gear used to go) to fill up with oil so I could use the designed drain bolt at the bottom of that chamber. It would add a lot of oil though so I never did it.
A 3d scan, and print in nylon could make this work. Nylon is cheap and should handle the oil and heat. I have a 3d scanner. I’d be happy to share some scans if anyone wants to work on a solution.
Nylon at 100% fill is roughly 40-50% the weight of aluminum. I think it could be done with far less.
Silicone closed cell foam is another option. It handles much higher temperature and supposedly is sold in liquid form on sites like Amazon but I haven’t used it before.
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