Thanks for the useful info! You're probably one of the OG rephasers if you did it in 07.
I can't tolerate the vibes past 5k, so I know anecdotally my engine must have a major difference from yours. We both have 76 447 cranks that were rephased by Hugh. I'm certain he replaced both of my rods but I don't remember what with, that was ~10 years ago! I used to have a GT1000 Ducati that was very smooth at mid to high revs and it had a long ass rod ratio, I also had a Vstar 1100 that was extremely smooth and it has a pretty high rod ratio as well. Neither one of those engines are counterbalanced, so I know it's feasible to make a 75-90 degree twin relatively smooth.
The bike starts with one kick, the jetting is close to perfect, the cam timing is close to perfect, the ignition timing advance unit is working perfectly. I just don't enjoy riding it because it vibrates too much. I suspect the crank is the issue and I need to bite the pillow and get another one built by a shop that can balance it properly. Since I'm considering having another crank built this is the ideal time to go with a different rod length. I was hoping someone would hop in and say "I've ridden a euro and american back to back, the euro vibrates less".
The thread's less than a week old, so some old timers may still wander in with their wisdom. It might turn out that wisdom is "get a better bike and re home this one to an enthusiastic youngster" which is the way I'm leaning. I've spent a decade tinkering with this bike and it's been fun, but there comes a point where you just want to be able to ride.