I think all those pics look pretty much normal. I actually use a thin grinder to cut the doweling while rotating it with my fingers. Only leave the center attached so I end up with a stick of spacers that I can take off one at a time as I need them. And managing to keep all my fingers in the procedure can be a challenge.
The charring should get less and less as the charred layer should act to slow down the burn process. However, if you have a severe overheat, this would give a deeper charring, but can't see it losing that much in physical length.
@Square4Life ,
if there is suddenly that much of a noticeable performance change, it might be worth taking the front panel of your PS off and ensure the switch assembly is all still firm. The switch is held in place by the shrink wrap tubing. Check the switch or tubing isn't slipping down from the work coil. If it is, PM me and we'll get it back in place. Can't think of anything else that would cause power boosting. Same batteries, correct?
If you guys want or need to adjust the Oring, it's easier than it looks. Just use a pin or even a paper clip and bend the end into a small hook of sorts. Push past the top on the inside and snag the Oring from under. I use the cap off a pen to push it back in evenly and stop at the top of button. Removal also makes it easier to remove the wooden spacer.
It should have being in the shipping notification. PM me if you missed it.
Home stretch for B3 Portsides and notifications will be coming shortly.