Thanks for the words of encouragement ya'll
... one trick my wife came up with was to use binder clips (like chip clips but used with stationary) to hold the cover in place during fitment, we were able to get a good stretch and alignment before fastening to the base. The foam we shaped with a hack saw and rotary sander, big mess doing that part but fairly easy to work with.
The engine is sounding very healthy now that I removed the mouse nest from the exhaust (that was the hot running problem on the first start up) and tuned it a bit, adjusted valves (only a couple a bit loose) and set up the points gap/timing....stab the starter or kick it a couple times, kaboom!! It is a bit lean sounding but I'll wait for a road test before any more carb fiddling happens.
Used the grease gun method to get the front caliper unstuck, read about that method here, worked like a charm....felt like cheating compared to the drama of using the air compressor! Was able to reuse everything, no parts, just clean and reassemble, might go for a brake line just to be safe but it feels pretty damn good at the lever.
Next up is to get the gas tank cleaned up. Again, I'll be using info I found here, there is a jug of 'The Works' waiting in the garage...then maybe a ride around the block..hehehehe!!!
