My concern about modifying an existing needle is that you will destroy the anodizing in the area where the needle is being modified. And it's my understanding that anodized surfaces are harder than bare aluminum, so the rate of wear in the areas where the needle has been modified will be greater than an unmodified needle.Posted by 'Dredd himself;
The KLX needle is the way to go. The stock needle can easily be modified to work fine, but the KLX needle is the answer.
I ended up in nearly exactly the same place with my stock needle custom grind and a 40 pilot compared to the 42 pilot and the KLX needle. (the latter does work better and less fuss) BOTH WITH THE O RING INSTALLED.
All this messing around because of not checking my jet drills. This is the set up i thought should work in the FIRST PLACE before i started messing with grinding the needle.
....not sure why anyone would want to bother with his one-off custom needle after he himself said this.