I decided to start the motor and see if my problems were any worse than a couple of stripped bolts. The standard prop bolts are 50mm, I installed a 60mm bolt in the stripped hole, and it torqued down fine. The exhaust wasn't going to hurt anything if it blew out of the header connection, but I had plenty of red silicon gasket material on it anyway, so I figured I'd be fine there.
After I got fuel into the motor, it popped on choke and started up very easy. A little tuning to richen the low end and transition was working pretty well. I didn't want to do any tuning on the high end just yet, only looking for idle and transition.
I have to say, the Tillotson carb was a lot easier to tune than most people have said, although the plane hasn't been in the air yet.
In a quick check on the ground, the low end is idling at about 800 RPM, very smooth. I was expecting a very shaky idle, similar to my older 3W 170. The high end on a couple of quick run-ups was about 5200. That's running a 29x12 3-blade Biela prop... that translates to just over 60 lbs of thrust, not bad for a 38 pound airplane. I'll look at high end tuning once I get a little more time on it. I think it's at about 1 1/4 turns out, and the manual suggests to start at 3/4 turns out.
Quick question 3W experts.... when I'm flipping the prop, I get a pretty strong "tick" just as the piston starts to get some compression on it. I always heard a little bit of that on my DA motors, but this is a little more than I'm used to hearing... is that normal as the roller bearings load up?