damn dude, sounds like you are having a rough time on all fronts.
couple of questions though. is this the mototune velocity porting deal? and if so, what are you going to use to decrease the size of the ports and how do you know when "when" has been reached (as in just say when). also, i take it the sanding you are going to do, you are hoping to create a small amount of turbulence right where the air and cylinder meets thereby creating a cushion that helps ease the passage of the rest of the incoming air, kinda like a golf ball traveling thru the air (thats why they have dimples, to create a little bit of turbulence to help them travel farther), aka Bernouilli's Principle.
Yep. It's a lot more work than I thought. But, I'm halfway there, so I'm gonna get er done.
And yes, this is the Mototune method of Vel. Porting. I will first use an aluminum cutter to gouge the floor of the port, then fill with JB weld as shown in your link. Once that hardens, I will use the sanding drums on my dremel to create the port choke point height. (35% of the original opening height) Reducing the opening by 65%
I will make a gauge (like a mic or caliper) to put in the opening often, to let me know when the optimal height is reached.
Once that is complete, I round the choke point with sandpaper, and rough it all over with 60 grit drums. (creating the turbulence and atomizing the fuel)
Wash all the crap out of the head, and put it back together. If I can get it milled while it's off, I will do that also, but funds might prevent that part.