Thanks everybody. Doug - I'm going to have it / them professionally plated & honed. I know that nikasil is actually a somewhat simple process on paper, but I know there's finesse in getting it right. Same goes for honing, so I will be working with a Pro on those aspects when we get there.
Here's a bunch of pictures, but a note on process. I read everything, all the books, weirdo Kart / Snowmobile / Jetski / RC Forums , the undisputed 2-Stroke beast designer that is Jan Thiel & his lovely Aprilia RSA engine... and try to reverse engineer existing designs to see what actually works in reality. When In doubt, I crack open Two Stroke Performance Tuning 2nd Edition by A. Graham Bell for cheat sheets.
The first cylinder I made in Seattle was basically a one-shot only art project. Which was dumb, but now I know better. This current design was figured out with math and formulas and copycatting. I drew up a port map, designed the cylinder in 3D, then produced 3D prints of the model with mold registrations already built in. I made silicone RTV molds of the ports (insides) and the cylinder (outsides). The port internals are cast in a sand/plaster mix, assembled then plugged into the mold. The mold is closed up and filled with hot wax. Basically Lost wax process from here on out.