Pull the studs out and get new ones. That way you/he will be sure they are correct.

Check out this blown gasket!

I wish I still had the pic of #2. When I pulled the head, the metal ring was squished and across the middle of the cylinder hole.

 

Clearly, you can blow a head better'n us! Looking at your pic, it's obvious that your studs are sticking up higher than ours. We/he is on his 3rd set of studs, all, according to the books, are correct, but I'm thinking something is REALLY wrong with the ones he's getting. He keeps getting the parts from the same guy, and I can not convince him to go elsewhere. I did, however, convince him to order stock, Harley, 1200 studs. We shall see.
Thanks to all that offered opinions. Much appreciated.
Frank

 

What 1200 kit did he put on it?

 

regarding the kit, all I'm getting is "big twin". Assuming that the studs come from them, who ever they may be, too.
Called up to Latus Motors, and one of their parts guys was kind enough to measure a stock HD 1200 stud, with a shoulder, and it's about 1/4" longer, above the block, than what he's using. That would put it right in line with the photos that woodworking posted.
I think we have a winner (answer).
Hopefully this may help someone else down the road.
Thanks guys

 

Sorry to revive an old thread, but this might help someone down the road.
Latus Motors (Portland Ore area) got it sorted out.
1st, the studs being ordered were not correct for this bike. Needed to be Harley, not aftermarket. After market studs are too short and don't have the shoulder.
2nd, and most important, is that according to Latus Motors, the head bolts on the intake (left side), for an '04 and '05 Sportster, are longer than on any other year. For those two years there is a specific head bolt used. After market kits do not seem to support that requirement.
Hope this might help someone else.
Frank

 

Good follow up info!