So, earlier yesterday I got to doing the exhaust thread repairs. Turned out well for my first time and all I kept thinking was, "why didn't I know about helicoils before?"
Drilled the holes out, used a pipe cleaner to pull the pieces of metal out, tapped and again with a fresh pipe cleaner pulled the bits and pieces out, locktite on each coil, installed new studs from leftover bolts from a pineapple bushing kit, dremeled the heads off, bolted the oem muffler on. Tapped the b5hs to .030 as recommended in an earlier reply.
Rode down the alley, let out the clutch, only got a pop here and there. Gapped the plug back down to .021 and had it started briefly.
Tomorrow when I wake up I'm probably going back at it again.
Now something I just thought of, the oz magneto came with a retainer plate and the studs that hold the magneto plates together are sticking out about a good 1/8 of an inch and the stock magneto studs were flush with the plates. I'm wondering if I should grind the oz studs flush with the plates or not?
I'll get some pics when I go back to working on it tomorrow. Here's pics of the motor before swapping mufflers