Crankcase machining ???

[Charles P]

Yes. I have. 
Not a task for the faint hearted, or those with a small milling machine.

Hi Charles, in a roundabout way I really would be interested in the cost to achieve a "As New" crankcase.
pm me please if interested in quoting. I'm in the early stages of creating an engine for a project that's under consideration, &
who cast these originally, recall seeing one at Beaulieu some time ago.
(Silly me, Who is Dave Flake)

I only do this for fun, not money. It’s a useful distraction from the day job in management consultancy. I know that even an experienced machinist will consume a lot of time on one of these so it’ll be in the thousands of pounds.  
I suppose that the question you have to ask yourself is will a new crankcase offer any meaningful advantages over a suitably strengthened original? Given that cars like Christian Pedersen’s single seater have original standard type crankcases you have to conclude that performance possibly isn’t the advantage so a new crankcase has to meet other needs, more along the Mallory and Irvine philosophy. 

Dave Flake was an excellent engineer who died about a decade ago. He cast these and some blown Ulster crankcases along with 10 stud blocks. Most of his patterns are with Tony Betts. However, I doubt that many crankcases have ever been completed 

Charles