Brian, that looks nice, thank you for the redesign. I am still holding out hope that once I get my tolerances better that it will run more reliably, you should not be sorry as you definitely warned me about it before I purchased the original plans, and you deserve to be paid for your time (I just cant pay as much as your time is really worth lol)
Tony, I don't think there is anything secret, a vacume engine by its nature is very low powered and requires very close square / straight fits.
I believe my issue is just that my cylinder to piston/valve fit is just a little to loose because I can get mine to run and run very well with a little wd-40 however wd-40 burns really quick thus my cylinder soots up as soon as it gets hot which only takes a couple of mins and then its tear down clean and start over. I cant get a long run because of this. (not supposed to run any oil what so ever but its the only way I can get mine going)
the reason I believe the wd-40 and other oils I have tried seem to make it work is because it increases the seal around the piston and valve to the point it has enough vacume to run. after lots of running / cleaning I am starting to see rub patterns in the cylinder which are not completely circular, I am starting to see slight oval patches in the cylinder that the piston has not rubbed which indicate not a perfectly (for lack of better description) "square" its darn close but not perfect so I'm thinking I need to re-lap the cylinder just a tad bit more which is going to require new piston and valve because of it thus I am going back to graphite since its sooo easy and quick to machine, and just because I want to.