I think the reason that your pistons are overextending into the barrels is
that you have the wrong crankshaft. Check out Harry Fenton's excellent web
site on Continentals.
http://www.bowersflybaby.com/tech/fenton.htm
He explains all the ins and outs of modifying Continentals. At our field we
had a Continental with a mix of parts, C-85, C-90, O-200 and that baby made
around 130hp! Never saw a Luscombe perform so well !
Wayne and Kathy Tokarz
Corsair Enterprises Ltd.
Cold Lake, Alberta,
780-812-8163
780-639-3023