the actual inlet that was machined out of the cast does not line up and turbulance is occuring here in green

When the blank housing comes out of casting, there is no hole for the inlet. At least not the last half inch (or it'* very rough). Eaton mills the opening, and it SHOULD line up with the bore that'* cast into the blank.

In this pic:

you can see where they missed with the boring to the LEFT, leaving a ridge on the left side. This is a major flow disruption.

The above two replies should tell the tale. Andrew was editing his reply above as I was typing the last one. Can you see the issue now?

I have the same exact thing on the 3 M90'* here.

Asked my machinist buddy and he said they use a reference point and go from there.

I smoothed and didn't find it hand fatiguing like you did. I probably spent 1.5-2.5 hours two nights in a row.

Bill, 75% of my 5th metacarpal (the bone between the wrist and the knuckle for the pinky) was completely obliterated in an accident. I lost 75% of the bone, and alot of the muscle and neve endings.

The bone is now comprised of a piece of the rim of my pelvis. And still retains much of it'* 'aftermarket' hardware. This was my RIGHT hand.

I've been working on both M90'* now for about 6 hours today.

I didn't know that.. ouch...

..I was surprised, you sounded as if this was hard work overall.

I didn't want to discourage others from trying. I felt it was reasonable.

Little known medical fact:

Your pinky provides 35% of your grip strength. This is what I was considering through 8 surgeries on my hand as I was facing the possibility of amputation.

I've been painting my kitchen during my 'hand breaks'. As a result, I've been doing Andrew'* porting on the dining room table, with a blue medical surgical drape over the tablecloth.

10 feet away from the wall I'm painting.

****... im gonna have a house painted van, and a house painted M90!

Bill is a great multi-tasker.

.....his right hand has a little bit of pelvic action goin on there.

Every time you shake my hand, Paul, you grab a bit 'o my arse.

Should be working the inlet on the GenV today. We'll be checking the plug.