Hey Matt,
I've got to hand it to you for taking a gamble on trying to save this machine. I went through the same thing 2 years ago when I restored my DA6191 solid tub. Except there were several changes I made along the way during the restoration. And one of them was the addition of a Suds-Return system.
Those screws that hold the inner tub to the agitator post assembly(8 #3 Phillips) will come out relatively easily, but my advice is to not remove them unless you really need to. I would recommend getting someone to help you if they must be removed because it is much easier with 2 people. I wouldn't waste my time with a propane or map torch, both take too much time and it is much easier to concentrate the heat source with Acetylene-Oxygen. Have plenty of Blaster handy and heat the area around the screws from the underside of the inner tub. You don't have to heat them, spray them, and pull them out all at once. Odds are they won't come out anyway. Heat each one a little and soak it, and go on to the next. You know how to do all that. Spray each screw again after you heat them and let them sit overnight like the fellas are saying.
When you go to take the screws out if need be, lay the inner tub on its side. Go to Lowe's or HomeDepot and get a #3 Phillips screwdriver about 12-16 inches long. Now here is where you need your help. Have someone heat around each screw slowly as you attempt to remove the screw. They will come out, but I guarantee it will be a heat and work type deal for 8 screws, but they will come out.
Be vigilant in examining the agitator post. I don't recommend scraping at any area on the post. My first choice would be a good wire brush either by hand or on a drill. An old vacuum cleaner works well for collecting all the soap dust and crud. I would say there is at least a 50/50 shot that you are apt to find perforations in the area about 1/2 way to 3/4 way to the top. These can be repaired with JB weld, but Metalset A4 works much better, and can be machined, drilled, tapped and painted or coated.
The rubber seals for the screws can be made from simple faucet washers if they are damaged when removing the screws. And screws that you take out, make sure you coat all of them with anti-seize before you put them back in.
I guess I do not know what was the bigger challenge in this restoration. Getting the machine apart without destroying it and finding all the parts to put it back together(anything I did find, I bought whatever the suppliers had left.), or putting a good suds-return system on it. Either way, new replacement parts are mostly NLA, and the information is not easy to find. So if there is anything I can do to help you, just ask. But I will be the first to tell you (cause I have been thru it) and the rest of the gang will tell you, restoring one of these "gems" if you will, is a good lesson in patience for anyone. If you like, we can chat via e-mail if you are in need of further assistance. Good luck and keep me posted.
Walt
