Ok thanks
I found a guy on eBay selling what he says is the original Honda OEM base gasket but he did not have a picture,Since I need two of them anyway I want to head and bought it and the price was right at $10 shipped.
Also it looks like I am going to need three gaskets for the intake,Looks like it’s running a spacer also

I just made my own gaskets for the intake, just went to the auto parts store and bought gasket paper and traced them out.

there are lots of videos on you tube for learning how to weld. get some scrap metal and practice. its almost impossible to tell someone how to do it over a keyboard lol..

You may be correct here.
I know the FL350 came with a metal base gasket -- it was aluminum.
I azzumed the FL400 was the same. Apparently I may be wrong.
I am talking about the base gasket NOT the head gasket or intake gasket.

Below is a pic of why I believe what I believe -- one is my Engine the other is my brothers.

I received a original honda base gasket in mail yesterday,it is a paper gasket

The base gasket can blow out. I had it happen to me on my FlL400. I believe I used Honda bond to seal it when using the paper gasket. I do recall it was gray color. Has held up well.

I have never seen a metal base gasket for the pilot, they are all paper, even the ones speed made. Rich is correct, use some Hondabond.

Oh I never doubted that,but I cant put a metal gasket on it when one was never produced

So as Adnoh had suggested on page 2{but I didnt even notice that till today }I was hooked up with Chris at CW Racing Engines.We talked over the phone for about an hour and he sure sounds like he has a lot of knowledge and time working on Pilots,and if Adnoh recommends him well then looks like I made good decision.I sent him pics and told him the story,he thinks I just ran in too long on that piston,rings wore out.He has the cylinder now,says I'm gonna have to go up to 90mm piston from 89.50 because of the ring wear.Which I was hoping I would be able to just go up to 89.75mm but he says no.
He says he knows the guy from Pro Design and he's going to see if he can get the O rings for the head.He hopes to have the piston kit by Wed or Thursday.I need to text him tomorrow and ask him how the ports look,see if he see's any problems

I talked to Tom at pro design. He made a couple different heads for the pilot. I sent him mine and he made me 2 sets. 20$ ea as I wanted a spare. He put it in the mail to me on Friday so I should have the head and o rings this week. So less than a week turn around. Great guy to deal with, answered emails and phone calls quickly.
Bob

Ok thanks.I was going to let you know if he could get some but you beat me to the punch

Kits showed up today

Excellent!
Chris from CW Racing mentioned to me the 2 smallest o rings,I did not them on mine,I don't know if I just missed them or they were missing,those go in the spark plug hole correct?

Here is a pic where they go. Inside of the combustion chamber. Do you know what cc your combustion chamber is?

NO I don't,I didnt know those parts separated,all looked like 1 piece to me

Received parts back from CW Racing.Still waiting on the O-rings from Tom at pro design so I cannot complete install today. Big difference in ring gap from before and after.Gap was so big before I could not be measured with a feeler gauge, almost 3 mm,now it’s.019

How much was the pro-x piston kit, if you don’t mind me asking?

He charged me 125 for it,I could have gotten cheaper On eBay but I also could’ve paid more for it on eBay, I thought it was a fair price especially considering all the knowledge he’s been giving me

Well got what I wanted to get accomplished today.Got to wait on O rings and hope they are the right size

When I separated the 2 pieces in dome there were a couple pieces broken off the center section.
I am pretty sure it would have had to have been like that the past 4 years because if these would have broke off while it was running I would think the damage(to piston and cylinder) would have been a lot worse?

I sent this pic to Tom at pro design(to make sure I was getting right O-rings)and he’s got some good eyes,I didn’t tell him about the broken pieces but he noticed them and said that would not hold that he would have to make me a new one,I emailed back that I was pretty sure it had been like that for 4 years(and I thought I was being very nice about it)but I think that just might have pissed him off,I don’t know,his reply back was short and he didn’t answer my other questions

I took piece to work where we have a laser welder we use for jewelry repair.I cut the end of an aluminum pipe and flattened it out and cut out some pieces and laser welded them in the spots that were missing.Not the greatest looking weld but I think it’s gonna work

I took the dome back to work and broke out the pieces I had laser welded in there and re-welded them,I Think they are a stronger weld now.I received the O-rings today and install them, then inserted the dome in to the head making sure that where the pieces that broke out that I welded were installed up against a wall and not in the openings of the head(the gaps)

Installed the head then did pressure test.It failed the first two times with 9 pounds of air escaping in 15 minutes.I could not find any leaks on the Engine anywhere, after the first failure I discovered that I did not have the spark plug screwed in tight enough and it was leaking there. Did second test and again could find no leaks on the Engine anywhere, ended up finding a fitting was leaking on air hose,it passed test after that.

I’m done for the night,Making a new air box with a new filter, this one is bigger than the old one, going to get another filter and use it as a pre-filter,Probably install it on the side as in picture

The repair on the dome looks good to me. I like the pre-filter idea! Are you using the Tupperware just to mock everything up or is that the actual air box? Might be tough to get a good seal on the lid.