I just came up with an idea that eliminates the small hole.
Here are a couple of pictures of the problem area.
This is the other side of the rotor housing from that
side I repotted on Marks engine.

Just clean this area up with a die grinder and hand cut
a chunk of aluminum that just slips in. Bond it in with
JB Weld BEFORE you cut the hole for the tube. Problem solved.

It won't help Marks engine but the Stainless steel sleeve
will do the same thing.
--  Paul Lamar ...No rotor no motor.

I have been watching this thread with great interest as I also   intend to
P-port my engine (to be installed in a BD-4).

Many pictures I have seen of P-port engines have the port cut at  an  angle
that more closely matches the angle of the trochoid.  Would it be   possible
to bore the hole at an angle such as this and still get the port   timing
needed for our application?  This would allow a stepped bore   without a gap
that needs filling.  The insert could then be a press or slip fit   and still
have the surface area to eliminate the possibility of leaks.

Bryan

Yes Bryan but I will not guarantee you will get the same
power as the Lemans engine that had a straight in bore more
or less. I don't expect it will be very much different however.
-- 
Paul Lamar ...No rotor no motor.

The angle make the rest of the intake too high above the engine to
fit inside most cowls  and also 90º and 180º bends will not work when
you are constructing the intake.  Jerry

Possibly.
The BD4 cowl is kind of tall I think. What say you Bob White?

He could cut a 180 degree bend off at the proper angle so the
upper leg was horizontal. Might be low enough.

Paul Lamar

I tried to do this once.  The result was a major form change where
the runner was cut. Also, after welding, there was some roughness
inside the runner where I over penetrated.  No way to clean it up.
Jerry

It must be cut on a radius line from the geometric center of the
centerline bend curve. Did you do that? In theory that is
still a perfect circle. That should be welded to the
outer 3/16th inch thick plate on the slide throttle. You
should then be able to get in there and smooth it up.

Paul Lamar ...No rotor no motor.

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