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For someone who doesn't know what they are doing you are doing really well so far.

I used to get a lot of stuff from Parts Unlimited bargain barn when I was working under The Ski Club as we were a parts Unlimited dealer, They would send out Bargain Barn flyers once a year , I never knew it was a full time operation, when I went out on my own I went with WPS, Marshall and WSM...

There are reasons, you won't like them, in a free market economy supply and demand rules, no way they could get that price for those pipes if the supply caught up or exceeded the demand, no worries though they have made sure that will never happen.

I can see both sides of this but if you have to set up a production run anyway and you have a market hungry for product why not make one large production run and fill that market need for years to come.

That is easily weldable by someone who knows what they are doing however insist that they weld it with the case halves bolted together and torqued, the chances of warping the case is great if it is not done properly

I sometimes solder them, but if I do it is after I crimp them

With a proper crimper I can crimp all seven before you can solder one, I guarantee it.

This is the other place I regularly but motorcycle terminals from they have the terminals and the crimpers, as Brapperdoodle said you need the crimpers .,they don't have to be high dollar , they just need to have the right shaped dies for whatever you are crimping...

They are motorcycle bullet connectors this place has any kind of them that you would ever want http://www.cycleterminal.com/bullet-terminals.html , look under terminals, you will need to measure yours as they come in different sizes but the 3.9 male terminals will work on the 3.5 female...

I really think a lot of the weight difference is in the exhaust manifold and exhaust, everything is much beefier on an 800, cases, crankshaft cylinders, head , flywheel, everything

https://www.x-h2o.com/threads/what-is-the-difference-between-the-66e-and-62t-cases.100802/#post-1169863

I used to make steering stem for X2'S that used an offset BMX bicycle steering head that the bars bolted to, a setup like that would move the steering back quite a bit. maybe something to look into AJP in Belgium makes a replacement steering head but I believe it is still straight...

Everything looked great till you screwed that plastic cover on top of the handlepole, IMO it detracts from an otherwise awesome build, on one I did I used diamond plate and sanded the diamonds down some, something along that line even if it was just flat sheet or cut down the stock plastic...

The tires make it float its all about weight versus flotation, if it has the 205/65/10 tires on it I have seen them float steel single trailers before, it makes loading and unloading a b!tch .

This seems similar to a KalGard type coating, I remember they used to bead blast pistons at low PSI and coat them for better thermal properties and reduced friction

Two things cause cases to crack, rod bearings going out or internal pieces of the engine got loose and got in between the rod and the case, either way you will be tearing that completely down and replacing whatever needs to be replaced.

I will say this much, I have run WSM coated pistons for years, I had a customer run one of the engines I built out of oil, the bore was scored up but all that happened to the piston was the coating was rubbed off, you could have literally bored another cylinder to that piston and reused it.

It doesn't matter anyway the people that spend money don't bitch , the people that bitch don't spend money, who said that I did.

Sorry I searched for it and came up empty , which in itself is very uncommon.

long time ago I bought an adjustable sanding block, it is similar to a contour gauge , it has a bunch of plastic fingers, you unlock it, set the contour, lock it then put sandpaper on it, it duplicates any contour, no idea where you would find one now though