Found a machine shop here in Malta. Bore measured and found to be out of shape. Piston to bore gap would have been .0075" if I dropped new standard size pistons in that bore. Decided to go .020" over. I gave the machine shop one of the new .020" over pistons and asked that he bore the cylinder with a .004" gap between piston and cylinder. They did a good job. Here's a pic of the freshly machined bore:
New .020" over JCC pistons with Hastings rings with installed ring end gap checked and found to be .010":
CNW barrel mounting kit made the barrel install easy:
Just waiting on a new set of pushrods from Norvil to install before the head goes back on.
Interesting to note that the pistons sit slightly proud of the barrel. This can be seen in the last pic above. Apparently this is correct for Commandos.
Cheers,
Joe