A happy ending
I'm finally getting to the end of this story I started months ago, and it has a happy ending. As I posted today in Snelling's thread where he shows his TWO 064s, I've finally finished my 064 resurrection with a Bailey's Big Bore kit; it took me months, but Brad just whips out beautiful saws in nothing flat!
Anyhow, it was a good learning process for me and as some suggested, I took my time and I also got help from my local dealer who did the bearings in the bottom end. Lots of starts and stops along the way, waiting for parts and other things that came up (wife now has a titanium hip!). I slotted the cylinder base holes as many of you described and it seems to have all gone well. As you'll see in the photos, this 064 is in less than cherry shape; front bosses for the dogs are broken, so I guess I'll just use one dog on the clutch cover--although this clutch cover has stripped mounting holes.
But she runs! I opened up the baffle inside the muffler; might do a DP cover later? Is that necessary if the side exhaust is one hole plus a gill slit from the factory? Can't wait to get her in some big wood!
The saw came with the 32-inch bar pictured; it's in pretty good shape. And the stickers on the covers? I put them on to hide where the previous owner etched his name into the plastic!
Thanks for all the help and encouragement from the AS peanut gallery. This task wasn't as complicated as I feared it might be, but the parts chase and back-and-forth was a big hassle. That's why I gave up on vintage motorcycles and that's probably why this will be my first and last rebuild! Now it's time to find out how she tackles big, old, rock-hard dry oak.
Olyeller/Ken