Hi again Grant. Yes old O2's will still work but at reduced efficiency w/o setting codes, MPG power and emissions will likely degrade on same path.
Plug gaps, Ron recommenda 20% over stock, so a .050 gap would become .060". .070 is pretty big, but you could pick easiest one to get to and add another .005" in steps till misfire then back off some, then put rest at that size, but .070 is pretty big.
Your home-made bit is cool, but not same as Ron's. If ya get a Personal Liscence setup and compare you'll see. I had a carbide ball bit cut down by a pro toolmaker for my iron Subie's carb base to save Ron's bits and he'd never seen anything like Ron's w/ 40 yrs. experience.
Don't sweat the gas-analyzer, just cup hand at tailpipe then feel/smell. Hot moist air there w/ no smell is sure sign of success! MPG calc's and driveability-power will tell the story.
Remember to do a re-learn procedure after re-install of TB, you will know within a few miles if you're in the zone.
Glad you're here Grant. I met Ron and the Groove 'cause of Peter Lindemann and Aaron Murakami as well! Definitely power-thinkers all 3 of those guys.
I'm guessing you are at/near Sea Level In Nova Scotia? Lots of moist Maritime air off the Atlantic. Good for power.
Keep comin' back!
Tracy G