The next step was to drill the holes in the Rear covers. Firstly I found the height of the cylinder bore as per below.
This was then used to locate the guide bar hole at the correct height.
Above you can see I have made a black mark with permanent marker on the interface between the two parts, this will be used as a locating point for future work.
Below you can see a scribed mark which will be used for alignment
A machined washer was then placed onto the cylinder face and aligned so the holes missed the steam passages. A mark was then made on the washer for location purposes.
The washer was then transferred to the rear cover boss and the two marks aligned for drilling.
A quick check of the hole to the left of the red mark on the washer clearly shows that if drilled, it will clash with the boss. A new hole, further around the PCD was then drilled in order to provide for the correct clearance.
Below the rear cover has all holes drilled and tapped. You will notice that the screws on the left side are slightly closer together to allow for the clearance mentioned above.
Here are the front cover holes drilled and tapped.
Here is a GA of the right hand side cylinder. All I need to do now is cut the screws to the correct length.