If I'm understanding what you are saying right if it's been damaged and repaired twice in the past and now it's a crumpled mess under the filler I don't think it's a simple matter of potting it in a former and giving it a good bashing, It's going to be stretched out quite a bit and will need...
Yes I'm sure it's overly rich and yes increasing to pop-off will lean it out but I actually think the problem might be the low speed adjuster (screw) is set to rich to compensate for the low pop-off.I would try leaning that out first as it's easy to do. Have you seen Group K site they have some...
First I would say that pop-off was to low, I like 20-ish and the bike is too rich. I would close up the low speed screw as my first port of call but I would find out where it is first by slowly tightening it and making note of how many revolutions it takes to close
I used to use N@C for parts over here, this is the pump I was talking about. When you say she dies when you crack it open....does she stutter and die or just bog down without the stutter? if that makes sense
Mikuni do a remote mount pulse pump, running one or two of these was the hot ticket, even better when coupled with a vapor separator such as the Novi one. I did mess with electric pumps but made the carbs a nightmare to tune as it messes with the pop-off pressure.
Just as a side note opening up holes from 7mm to 8mm is a hard task for any hand drill as the bit pulls itself into the work and you end up taking a very big cut.
The amp/h tells you how long it will go between charges. I would get a brushless body only and a battery as its the most cost effective if you already have a 18v charger.
It used to be taxed within the last six months so in theory the mot can be 18 months old and they used to inspect random cars, I've had a couple checked.Not sure if any of this has changed now though as I haven't done a transfer in years.
I would get an old screen and see it you could scrape of the element and then polish the glass,I damaged a screen with a one sided razor blade cleaning off some overspray and the element seemed to come off very easily.