Redshark - glad to hear you've enjoyed the thread! The forum definitely keeps me going on the bad days - good advice and a place to vent when you need it. Not like the wife wants to hear about my bike project is sucking.
Anyway - good call on the Raptor petcock - I think it's what I have on my KLRE. I'll take a look and see what I can find. I still have the old tank to play with - thanks for the measurements, Zap! I really don't want to play the de-fuel game unless I know it's for a reason - measurements definitely will help.
Looking back, it's funny that I called out the petcock problem before I even knew mine had failed. Go figure.