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Well, after having had a big slice of humble PIE!, I called the nice folks at PM Research, and have ordered a new cylinder and a new inboard head casting. I think I am going to continue with the cylinder as is so far, because it can be made to work, and then with more hours and experience under my belt later on I'll make the new one to replace it. For the inboard head I may make one out of brass stock in the meantime, see where I went wrong on that.I ordered an engine #5 at the same time as ordering the new parts. Looks like a nice engine from a couple of threads here, so will be another fun project.I am not going to put this engine aside though. I'm going to keep on it. I may not be doing very well so far, but I put that down to inexperience. I've had my shop and tools for quite a while, but don't have many actual hands on hours on them. Now that motorcycling is not my main pass time, and I'm selling off all my bikes and replacing them with tools, this hobby is becoming my number 1, and so with more hands on time will come better results. If I don't get things right first time, then I'll do them again. As long as my working practices are safe, and I'm not catapulting chuck keys across the shop then I'm happy.Oh, and I have to fix the drive system in the lathe apron. That job is up first.Carry on.
That's why I went with PMR kits as my first casting builds. Good availability of parts makes for a little reassurance.
I have the kit for a PMR #6 waiting in the wings. I'm still not at the point where I'm brave enough to touch it...