If it's cast onto the flywheel use a small square needle file. I mark the key with a black marker so I can see how much im taking off. I also go 1/3 on the cast keys.
I have used card stock, beer can and FelPro .015 gasket material to lower jugs. Measure stock squish and find material to drop it in the .020 range. I usually take .020 off the key for timing advances.
I also use Anchorseal for my slab ends as well as my blanks for my lathe.
A larger log would be best if you're looking for 16" slabs for the bench. Avoid the pith.
I haven't seen any issue with the two cutter on the same side at all.
When spinning up rivets I have seen some cracks and haven't had any issues with those either.
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