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2 different plugs may do it

I would, love to here, many others also.

Compression is an indicator of potential octane required, that's it.
How well that octane combusts is they key.
Squish/ign timing/pipes/transfers all play a big or moderate role adding up to more that just a compression test.

technically no. but it can be done, i would not recommend it. with an ex race bike, its worth splitting the cases and doing a full inspection.

trust me, i've had bikes that 'ran'. one had a blown crank seal, the other was missing half a piston.  thersa slew of horror stories i can rehash.

always worth spending an afternoon to go thru the bottom end, re-gasket it, and replace anything suspect due to wear and know exactly where you stand. a gasket set is cheap. crank seals are cheap. good insurance.     

Elaborate why teflon is not your favorite. Please?

I have always wanted one.

Teflon tipped seals!
Plastic main cages!

That's what I wanna see.

Aluminum A383 or 360

Hmm, at least to my eyes, those PWKs look more "streamlined" on the air filter side than the stock VM28s. I wonder if anyone has done any flow testing of VMs  vs PWKs?

Yes, Vm34 short bodies.

Sand blast

So...?

90 psi is barely starting.
Bad gage I suspect.

Kaw's have an o-ring that gets smash smooched for spline sealing.

Any updates?

6-8"

Which engines have you played with?
I have some play time with Yam 100,sirio and a little $3000 50cc italian jewel Comer50!