88Turboii, it is redundant work cutting both sides of the corner seal, you only need to cut the one at the leading edge of the side seal as the rotation of the rotor against the side plate will maintain the gap tight at the trailing end, thus you only need the "labyrinth" at the leading end of the side seal to allow seal expansion without gas bypass.
Thanks for the detailed reply
Barry. Perhaps just one photo from 180 degrees of the existing one so I can see how much of the rotor you have used and the way it approaches the seal.
I think I will try to put a jig together, as it happens I already have a diamond bit which looks pretty close (although I would make sure I had several of correct thickness before starting) and dremel style tool although I might not be pulling the motor for a while, I suspect I may have to make a career change to get cash flow happening (I'm hoping I don't have to sell one of the 7s in the mean time). I would certainly make any jig or tool I put together available to other rotary community members here, I have happily volunteered my time to help forums members (rotary and otherwise) with various bits and pieces before. I have learned a bit about air cooled porsche motors in the last few weeks, getting intake and head studs out isn't always fun, and they can run without head gaskets
