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Well, I borrowed some very good heat exchangers from a friend, and did some more measurements. It's actually easier than I thought because the 2 stubs are actually parallel and only the stud pattern is offset. It's so much harder to try and take the measurements out of the heads..
The good news, is that the cyl.1&4 stud pattern seems perfectly centered, eaventho it looks a bit off because of the shape of the 2 "ears". So I only have to do one more plate for the cyl.2&3 jig. That one has the holes offset by 3mm clockwise (looking into the exhaust port). The tabs will definately need to be trimmed to fit in there. The oval flanges fit very well inside the ports. This is how I measured: The tail of the big caliper was sitting on the other stub.
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