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My caution about removing the baffle is based upon an 038, a saw that I know Al has a lot of experience with. Opened up the exhaust exit to 3/4" and removed the baffle plate, that just slips out when you take off the muffler cover. No way I could get it to idle without the chain moving at...

Sometimes removing an entire baffle can give idling problems, if you open up the exit too. Not enough back pressure, the saw won't idle at a low enough rpm for the chain not to spin without the engine dying. You'll be wishing you didn't remove it.

Specs at max 13000 rpm.

As all mentioned, and I'd like to again emphasize, putting a chamfer around the inside port openings is very important. One lacking in a sufficient break on the edge, will chew up a ring very quickly. If the ring should break, it can be an expensive proposition to get the saw in good order again.

If the piston doesn't slide in easily, don't force it, as a ring has possibly shifted in it's groove. Ask me how I know. :|:

Nice looking exhaust port on that saw.