Thanks for the replies. I know, I need to get pictures up here! I need to get serious about finding a replacement for photobucket.
I'm thinking the body is warped because the kit comes with two hoods, neither one of them will close correctly. I don't think its hitting anything, it's not pivoting over the air filter.
I've built flintlock rifles before and fitting the brass patchbox lid kind of reminds me of this problem. But it's much easier to tweak the wood and brass to get a good fit. On this, it looks like an adjustment or shim here will change a line there, etc. You just wind up chasing the fix. I'll try heating the hood and trying to get it to conform. i don't think it will work, there is nothing to leverage it against to get the right bend and it's only off by a very small amount. But enough to look bad!
I might just build it hood up. I guess I could put a Masterbox pinup figure in, but then it wouldn't be my eight year old's model anymore! And that would be fine, I just picked up the Snap Tite Grave Digger model for him, and that's more his speed (for now!)