To get a good uniform finish on the cast engine parts and the sheet aluminum cover we made, there was not much choice but to blast off all the remaining powdercoat and start over. I covered the cylinder gasket areas with some plates I sawed out of Trespa. Getting the powdercoat off turned out to be quite a challenge, but Johan Heemskerk got some extra sharp grit that finally got the job done.

Now that everything was bare metal again, I worked on the gaps between the various parts. Using masking tape as a guideline I filed the parts untill the gaps were even. I also had to use a nylon hammer in some spots to make the cover blend smoothly...