Before you put the head on, another thing to check is to rotate the engine carefully and see if the piston SKIRTS clear the flywheel when the pistons get to the bottom of the stroke. Good to know.

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GrandPaulZ
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This maybe completely wrong but i am clutching at straws here.

'Later' 750 triumphs had a shorter con rod.. I do not know when 'Later' was.

but is it possible you have a shorter than normal conrod ??? maybe a PO did an 'upgrade' ???

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A wise man learns from his mistakes..
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Just double checked all my measure.
Everything is fine, Stroke etc.

The pistons were purchased from british spares (NZ) and they look identical to the ones that were in the bike. Correct part numbers etc.

Maybe i have a phantom aftermarket asian Barrel?? someone told me about them.

I think i will have to shave 1mm off the barrel. I doubt it will distort the barrel.
if i need to make it up i could run a thicker head gasket or use a couple of base gaskets

Otherwise ill have to source another barrel or buy a bike that is running!!!!!!!!!

I did see them (barrel on UK ebay) brand new standard barrel & pistons for 189 Pound or something plus $100 pound shipping to OZ.

Cheaper to buy a new bonnie when you triple that total to get to aussie dollars

I would strongly advise against shaving the barrels until you know what the compression ratio actually is, as i said before. Be wary also of packingthe barrel at the base gasket. this will run the cam followers lower in their slots.

At £189 it seems not so bad, a new barrel for an Enfield is about £130+ which is only one hole ( why do holes cost so much??) and for a BMW nearly as much ( and you need two).

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A wise man learns from his mistakes..
A genius learns from other peoples mistakes.