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How thick is the solder?That’s without the gasket. I was expecting closer to .020 from what you’d mentioned previously
Something is wrong. On oem 026 jugs they are generally head slappers or too tight to run without base gasket. On the 44.7mm 260 jug (which I think you have there-you haven’t confirmed size yet that I have seen) you can usually get away without gasket but it’s tight.
If you are using solder that’s way too thick, or just rocking the piston back and forth a few times to squish the solder, the readings can be off a bunch. I use .026 solder (I think it’s .6mm) or .030 solder and I spin the saw over from the crank nut with a drill. You can also install and pull the starter rope a bunch of times. When it’s right, you shouldn’t feel the solder when you rotate the engine. If you still feel the solder, your measurement is wrong.