I've read other posts where guys cut timing the cover. I presume the cut is made centered at the 3/8" diameter holes that are directly above the dowels. This lets the 3/8" bolt continue to impose clamping force on both the upper and lower halves

I imagine this any easy task on a band saw. My question is how to account for the resulting gap that would presumably be the width of the back saw blade.

Are folks welding a strip of metal across the backside of the the lower half to function as a backer for the RTV applied after halves are installed....or what ?

Thanks in advance.

 

Yup, just weld a thin backer onto the bottom piece.