After polishing with 400 and 1500 grit wet/dry, and then cleaning, the cylinder 
went right back together in the reverse order, as predicted by Tony and Sam. A 
compressed air test with the engine reassembled now showed that the other 
cylinder was leaking air past the o-ring. The engine ran better, but still not 
smoothly.

Since the tools were all out on the workbench, I went ahead and disassembled 
the other cylinder. It wasn't full of debris, but it needed polishing.  Within 
2 hours it was back together with a new o-ring.

On air the engine would start up and run smoothly. The cylinder action was a 
bit tight but smooth. Under steam yesterday, however, things were not great.

The boiler raised steam in 5 minutes, and intitially the engine seemed like it 
wanted to run. But then it got very stiff and would not turn a full rotation, 
almost like there was severe priming. (Also the first cylinder's head leaked 
steam, although the head was fully seated and  straight.) This continued until 
I shut the fire down. Subsequently it ran again for an hour on air down to 10 
psi just fine.

Causes?  Possibly insufficient steam volume. Possibly the o-rings are still too 
tight and the piston's expansion with heat makes them tighter. Possibly 
priming. 

I will try it under steam again before tearing into the cylinders again. Maybe 
rig up a superheater to dry the steam a bit before it goes to the engine.

Steve


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