I think you need to take it to an engineering firm and let someone who knows what to do with the right equipment deal with it.

How is the nightmare we need updating

Thank you very much for the cheer up..

Havent had the time to work on it. Giving it a dash of penetrating oil and a couple of knocks once or twice a day. No result.. yet

Got in contact with a trial fellow from the neighbour club last night that works at a metal workshop. He was more than willing to give drilling a try, but couldnt say when he had the time.

-Jan

Edited September 17, 200916 yr by JanDyb

Well could be worst ive stripped mine and rebuilt it only to do it again to have to replace main bearings and several gearbox bearings seals and an idle gear and then piston n rings little end

cheer up yours is only a small issue

Don't be to worried about heating the magnesium, it is only flammable as thin slithers or dust but saying that don't go mad at it with a blow torch, a electric heat gun is preferred.

I'd have a go at drilling it as well, you can do it with a cordless drill if your careful.

Well could be worst ive stripped mine and rebuilt it only to do it again to have to replace main bearings and several gearbox bearings seals and an idle gear and then piston n rings little end

cheer up yours is only a small issue

Been there done that... Had my 04 300Pro open 5 times earlier this summer before getting the crank seals to... ehh... seal.. Sold it as fast as I could a couple of weeks ago and are taking over my sons 06 125. Was converting it to a 200 when I got the idea to paint the casings...

So this season i have only ridden one competition, and that was on a borrowed bike. Great! (not)

-Jan