Print #7 is a success! Seems to hold air pressure (very un-scientific "plug holes and blow into it" method), but good enough to test drill/tap etc. I'm still not satisfied with the overhang surface quality and the top of it is a bit rough too...
The first thing we checked was that the engine was not seized. It turned over easily by hand. Too easily, in fact. Did a quick visual on the timing and filed off a little nub that had developed on the points contacts, poured a little two-stroke...
OK, after wrestling with the design a bit (mostly getting comfy using Fusion 360), I have a prototype design that uses 1/8" NPT brass fittings and brass M6 heat inserts. Ordering some parts / taps and will be printing out the first prototypes...