SHADOW sent me his Pilot cylinder, I forget where the thread is he talked about it.

Can you say poofkaboom? I will let him give all the details so I don't screw it up heh

I think he used up his entire stamp collection shipping me the cylinder.

Some as found pics of the cylinder, plenty of aluminum stuck to the cylinder, muriatic acid will removed this.

The tabs on the exhaust manifold are about worn out.

Reed cage

Some nasty flow inhibitors ...

Now the intake exhaust and studs are remove its time to remove the aluminum smeared on the cylinder walls

Once the aluminum was removed I took a new stock piston to check the clearance the quick and dirty way, that's a .005 feeler gauge this cylinder will need bored to the first over bore.

LOL. the new lady at the post office does'nt know how to use the postage machine. Do you think i can weld some material to the ex flange to build it back up? I went ahead and sent the reeds just so you can take a look at them.
They looked fine last year when i took a peek inside.

Update, I remove the studs, exhaust manifold, reeds and intake, lapped the top of the cylinder so its flat again, bored and honed to fit new piston, beveled the ports, I cleaned up a few of the real nasty casting flaws too, their was a huge one in the exhaust port.

I touched up the exhaust manifold pretty much the same as done here http://pilotodyssey.com/manifoldrepair.htm
I put some copper wire in the holes then welded it a little, file it down then bevel up the back side of the hole like factory.

Still gotta install the studs and go through the reed cage.