After pitching the blades, I went back and removed the whole prop from the engine, sat the hub on a level block above the bench and measured from the bench to the LE and TE of the tip of each blade, rotating the hub so that each blade was measured at the same spot.
Happy to find the measurements were the same to the millimetre (LE-LE-LE and TE-TE-TE), so no difference whatsoever.
My Mr Funnel arrived yesterday so I grabbed 20L of petrol and headed up to the plane.
Tested the fuel system bit by bit, apart from some tightening needed at one connection it was all good.
Some learnings:
Mr Funnel is excellent but not particularly stable when balanced on the tank neck. I will print up a support stand with the profile of the wing surface at the bottom which centres on the tank neck, with a circular rim at the top to hold it steady while filling.
My Sav header tank does indeed have an additional 1/4" barb for a breather tube. I will have to fabricate another line back to the wing and a T in the hose that goes back to the top of the tank. For today I just put some 1/4" id PVC on it and into a bucket until the header was completely full, then crimped and clamped the hose.
Tested the two tank taps in the cockpit individually, checking that each was pouring at about the same rate into the header. They did. Then both on and the pouring doubled.
I then took the hoses off the carbs and into buckets, and opened the cockpit tap. This resulted in a fast drip on each side but no real pressure. (Assuming that when the engine is running the mechanical pump sucks it through).
Next I made sure a fire extinguisher was within reach and held my breath while turning the key, then hit the switch to the electric pump. This caused both hoses to jet the fuel out quite nicely. I hadn't put graduation marks in the buckets, but it looked to me like at least 1L/minute on each side if not more.
I was running out of time so didn't get a chance to put the hoses back on the carbs and test the fuel pressure gauge and return line, will do that next time.
Drained the system from the lowermost point at the bottom of the header tank (looked for all the world like the plane was squatting and having a very long piss) and looked into each wing tank, confirmed they were both empty. Used Mr Funnel again to put the fuel back into the container.
Very happy that the system seems to be working as designed, with no leaks!
In the 2 pictures of the header tank, you can see the difference between having the breather crimped off first, and letting it fill and THEN crimping it off. This confirms what @IBob said about the early tanks not having a breather and the low fuel sender going on and off. There's a definite air gap under the sender when it was crimped first, where in the second pic you can see that the tank is completely full.
...when ya gotta go...