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I have the 498 cc blind head barrels from my 1930 TT Rep in good condition other than being worn on the bore. These are 40 thou oversize as are the pistons complete with rings and gudgeon pins.
Eddie Shermer was going to bore out the barrels for me and turn down some 600 cc pistons to make up a 540 cc motor.
However, I managed to obtain some 600 cc TT Rep barrels and he used these instead (as the 498 cc crank cases had been changed to 600 cc by a previous owner) to match the crank cases.