Well, it looks like we are getting somewhere at last. The "*#$$%$#" cylinder appears to be the problem. We took the cylinder off the other machine and put the "original" piston and sleeve in and it worked fine.Nary a bubble to be seen.!
I nearly did a cartwheel.!
On looking at the cylinder we "think" that the lip on which the liner rests has been damaged somehow - as its a static liner, its a mystery, maybe when the piston siezed it caused the liner to be moved and damage the lip, I dont know, but on "VERY" close inspection it had a distinct burr and looked gouged,-unless you sat and looked carefully for it, its not something you will "just see" - well we didnt anyway, we think this caused the liner to be sitting slighlty "off" or have a miniscule amount of movement even when the head was was tightened down, - so we sent the cylinder to have the "lip" machined straight and the top of the cylinder "skimmed" by an equal amount - we are talking very small amounts here, a few thou I would guess.
Bauer did not have a spare cylinder so this is all I can do. Believe me, it took the best part of the day tuesday to decide what to do, I could get a generic cylinder, -
what is your opinion on this, are they of the same quality as the genuine Bauer product?? - I didnt know and wasnt prepared to chance it, so I went the machineing route.
If it all works out I can order a new cylinder and if it takes a month or two to arrive its not an issue.
I will get it re-assembled tomorrow and see - Boy, am I hoping...........!