I just bought a tiny Davies Craig cooler for mine, it doe a pretty important job so I wouldn't risk anything marginal. (look at most of the DNF's back in the Group A days and they were steering related after cooking the pumps)
Dale: As long as they don't extend under the gasket sealing surface they'll be fine, there's a limit to how much you can remove from a 7M head the surface isn't that thick.
On a related note I saw errosion like that starting using Green coolant on a brand new block within 2 weeks :(
Grab a sheet of sandpaper fold it lengthwise a few times so you have a strip then wrap it around the hub and sand like you're buffing a shoe.
Turn the hub a bit and repeat until you've done the full 360 degrees.
Just DON'T sand in one place too long and it'll be fine.
I was discussing this with a bud last night and taking the 2 most powerful domestics on the Aussie market for comparison I've spent less get more power and far better economy with my Mk3.
(and goes without saying in a MUCH prettier package)
ALL of the mechanical wear items in my car are new...
Fit a new tensioner and spring.
The belt tension is set by the spring alone the procedure is detailed in the TRSM.
Word of warning do NOT exceed 36 ft/lbs for the tensioner bolt, if you do you will deform #1 cylinder and cause blowby.
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