So here's what I'm working with.  '87 Savage.  Stock motor except for KN intake and custom exhaust.  Big City Thunder baffle inside basically an extended header.  I live in Greenville, SC in the foothills of the Blue Ridge.  As of now, custom bars, seat, wiring harness.  Basic bobber project stuff.

Anyways, everything is done except for the carb.  The long and short of it is that I had a stuck pilot jet, drilled it out, but the threads were damaged.  I tried tapping, but I lost too much material in the body.  I don't think there's enough there for a helicoil as the wall is just 2mm where the pilot jet is housed.  Tried building it back up with JB Weld, but it was just two thin to be strong.  blahblahblah.

The obvious solution is to just buy a new stock carb, but they're running $130-170 on eBay, and you still don't know what you're really getting.  Having my carb machined with an aluminum rod in the body or something would probably be just as much.  

Now to the question:  Will the BS40 carb work?  Not the stock BS40SS, but what I assume in the mechanical version of the stock CV.  These can be had a bit cheaper.  Also, are there any other great alternatives for carbs that any of you have used that may be cost effective?

I'd appreciate any thoughts any of you guys have.  I've been challenging myself to do this thing as inexpensively as possible, so I'm willing to exercise some ingenuity if you have any clever ideas

I got my old carb fixed.  Just wanted to write on this thread in case anyone else ever comes searching.  

I completely drilled out the old threads in the pilot jet port on my carb.  Then I took a 2 in piece of copper tube (approx 3/8in dia.) and cut sections out lengthwise with a cutoff wheel on grinder.  Basically I kept cutting and clamping the copper tube together until it fit-ish.  Then with some sanding and whatnot I was able to tap it down into the port.  Then all there was left to do was thread the inside of the copper tube/sleeve and we're back on the road.  Its not an interference fit so some may balk at the cheap fix, but it was a heck of a lot cheaper than a new carb.  And it works

Great work!

I like it when ingenuity triumphs over dollars.