Feeling like a real idiot with this one...so I just put my Verslavy in.  It was easy and quick, and is looking much better.  Fantastic!  I wish my story ended there.  
While I was waiting for the part I decided to adjust the valves and solenoid while the bike was on the lift.  That part actually went okay, everything sounds better, and rides well.  There was a little bogging at first, but it seems to have worked it's wat out as it warmed up
Of all the things that could go wrong the problem is that timing port cover wont go back on.  I tried to be easy on it, because I thought I was cross threading it, but that wasn't it.  Checked for any metal shavings in the threads, nope.  It seems like the outer threads were marred by the offset wrench when I was trying to rotate the engine to TDC...as a noob it took quite a few attempts before I got it right.
I was able to get the port cover started just a bit, but then it wouldn't budge.  I pried it on as best I could, but it is still sitting off from the case quite a bit, nowhere near flush.
Trying to find out my best options for this one...am I screwed?
I was going to buy a replacement port cover for a Volusia that I saw on here that uses a hex wrench.  But now I'm afraid I'm going to have to buy a whole new engine casing.  Is there any hope for this case/cover?  Can I rethread the port somehow?

Also, is it rideable in this condition?  If it isn't sealed I dont want to be getting junk in the engine...

As you explain it, you've mared the internal threads.

take some scotch brite and debur the threads.

I agree,, it wouldnt be a long term thing, but if I HAD to ride a few miles to work,, thats how Id go at it, IF I couldnt fix the threads in time,, but getting those threads right is simply a Must Git 'Er Done" thing.

Not to mention the oil that would be leaking out there. Mine leaks with the cover tight and a supposed new o-ring. I doubt that duct tape would hold.

You could get the version of the cover made for the C50. It has an Allen wrench socket instead of a slot. With everything cleaned and lubed, you can crank that puppy in there.

Part # 09259-36008

I picked one up at one of the shops I go to. It was cheaper to have them order it then to get it shipped.

Just updating...so what happened was that the outer-most groove on the stator cover got bent over into the next thread.  Just took a sharpened flat head screw driver and carved it back out being careful to not get any metal inside the case.  It's tougher to get the plug on/off now, but it's fully seated again.  Took it for a short ride, just to heat up the oil, no leaks, so I think it's better for now.
For what it's worth I found out that the small flat blade on the side of a painter's multitool works REALLY well to loosen/tighten the plug.  Too bad I marred mine all up before I figured this out.  Will be replacing with the C50 part this weekend.