In hind sight the jb weld idea was not great but I guess I was just frustrated and figured what the hell. It actually did fix the issue I guess (to some extent) and actually looks pretty good but it really isn't a long term solution.
Agreed. I don't think the cylinder would be able to move much as the pushrod base is up against it and everything I think is lined up enough so the exhaust and intake would seal up properly. But for the money I have into this motor I shouldn't have to be doing any jury rigged solutions to get things to work. I'll contact Hammer tomorrow. They may give me a hard time about drilling the cylinder but it was toast anyway so it's not like they could resell it if I send it back. It's one step forward, two steps back with this engine lately. Rebuilt the whole chasis only to have the motor go south on it's first ride out with a top end that was only at 3500 miles. My garage is like a used parts warehouse right now. I have 2 1/2 motors apart in there.
TO help you feel better; I have 15,000 hard miles on my 1250 sporty with 495 cams. It only just started seeping on the front base gasket. I expect it to go a lot further before it gets addressed. I'm running Buell heads with 15deg squish and 15deg pistons. It's be worth the blood, sweat, and dollars. Fun fun.