To Rob:
Thanks again for the tip to source the aluminum washers.
To all:
I chucked an assembly similar to Robs in a drill press, and while it was rotating, sanded the group down to 0.410" dia. with a Dremel drum, finishing with a file and fine sandpaper. It went well, did not take too long, although it wore down 5 or 6 Dremel drum sanding sleeves.
I am using Jim Schmidt's fiberglass reinforced silicone timing gasket. With these washers under the heads of my socket head cap screws, and Jim's gasket, I am able to torque down the screws and I have finally eliminated that oil weep that has been ever present at the bottom edge of my timing cover for so many years!
I turned down enough to use on my gearbox cover, but as yet have not installed them.
Atlas Report: My Atlas has a Comnoz rebuilt head, new 9:1 flat top pistons (down from 10.5:1), newly rebuilt K2FC by Doug Wood, and I am in the process of converting to LED lights. I now need break in miles.
It runs good, no leaks, 'nuff said.
Slick