Thanks for all the helpful suggestions.
So if I order some tube how does one remove the ends from the old rods?

Got one from a club member (Thank you Mark).
Still looking for one more - has anyone got one hidden down the back of the sofa?

Thank you everyone for your suggestions.
In the end, as I managed to borrow a compression tool, I decided to put the piston in from the top of the barrel.
This went OK and with some generous amounts of heat to the exposed gudgeon pin area, the pin went in nice and smoothly too.
On to the rest of the ...

Proper old school fabrication
https://youtu.be/aerdr95Bf4Y?si=3G3HU9fanEfBoq5u

Thanks Roger, most helpful.
Good idea to try it off the bike first .

I have to put the piston back in my barrel. Bit worried about breaking a ring.
Is it easier to install it first, from the top, then lower the whole shebang before fitting the gudgeon pin?
Or lower the barrel down onto the piston after attaching to the pin?

either way, what sort of compression tool ...

Roger Gwynn wrote: Thu May 14, 2026 11:27 am I would suggest honing the bore by half a thou, (.0005"). .005" is the bottom limit for clearance and I would aim for the median of .006". My VA used to seize if it was thrashed, took half a thou out and it has never misbehaved again, well not by seizing anyway.

Thank you, Roger.

Currently have Hepolite 4173 (86.4mm) but have been suffering with seizures (the bike, not me).
Done 100 miles so far. Bike always starts after a few minutes, not sure what my options are here?
There is 5 thou clearance top and bottom, the rings are free.

nevhunter wrote: Fri May 01, 2026 1:05 am What Bike is it, may I ask.? Nev

500 Red Hunter (now added to my signature )

Yes, in the end I decided to fit a spade end and thumb nut on the plug - looks right for a 1933 bike