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I fixed it
Thanks bud.
Roughed in with a DC Carbide burr and finished by hand with a Nicholson Mill Bastard file.

Took about 0.030-0.035" off each face.
Still have a bit further to go.
I need 2.3875" min to make it fit.
Gonna shoot for for 2.375". Should give me some wiggle room.
What is the way to get the cylinder lined up on the crankcase before tightening?
 
Before I sent my case to get powdercoated I took some off the case. My cylinder isnt here yet so ill see what I have to take off when it does.
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What is the way to get the cylinder lined up on the crankcase before tightening?
saw the heads off a couple bolts ,finger tighten them into the case ,now you have alignment pins to work with ,i leave the recoil cover off ,and roll the flywheel around to cycle the piston up and down to check clearance skirt to case .
 
saw the heads off a couple bolts ,finger tighten them into the case ,now you have alignment pins to work with ,i leave the recoil cover off ,and roll the flywheel around to cycle the piston up and down to check clearance skirt to case .
Makes sense. I never knew exactlty what to do so I left all 4 barely loose and worked the piston several times thinkin that would self center?
 
Heck I dont know!! Lol!! Only thing I knew to do!! It ran really well and never blew up and was taken apart several times. I was paranoid in my mind thinkin whether or not it was center . If the holes werent oblonged symetrecially would it be possible to get it off centered front or back?
 
Heck I dont know!! Lol!! Only thing I knew to do!! It ran really well and never blew up and was taken apart several times. I was paranoid in my mind thinkin whether or not it was center . If the holes werent oblonged symetrecially would it be possible to get it off centered front or back?
If you use an ms440 base gasket and eyeball it center you will be fine ,as long as the piston goes up and down without binding or rubbing ,you did good .
 

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