2003 400ex chain drive too short

Got all my pieces for Christmas and installed the new drive sprocket (13T) new driven sprocket (38T) and a new 520 xtg chain. Made the chain same size as factory chain and it was too long. It would touch the skid plate. I removed another link and side plates. Now the chain is half a link too short. I cannot get enough adjustment on the slack adjuster. To topf it off on one end i broke a roller so that link has to come out too. Would i be able to add a half link and maybe rivet the repair in?? I know DID has a rivet link but i cant find one for sunstar.
I repair non oring chains (#40 - #120) alot on industrial equipment so im familiar with half links and adding aditional links with cotter pin style links and master links. But thats low speed 200 - 300 rpm and high torque.
520 chain seems to be voodoo magic to me.

What should I do at this point?? Help im dying to try this sprocket combo..


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go ahead and get ya a half link ... the 1's with the pinan cotter pins will work just fine ... but keep a spair just incase ... and after a couple rides it should be stretched enough to take out the half link ... i have had to do it b4 in a few of mine ... i have a polaris 350L that i have 10 different sprockets for that i drag race and have a few chains and use the half links with no problems ..
the polaris 350L has a snowmobile 600 tripple motor on it .. an havent broke a half link on it yet so far...

That was my next question. Use the half link till it stretches enough. Got it

Now where can i get two links? Think the dealer might have a couple laying around?

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Also can i adopt you CK?

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lol...dont know about all that shit ...but if ya want you can send me some good riding pics of your riding trips.. ill add them 2 my collection .. i have 8 thumb drives full of riding pics from all over the us an a couple other countrys

Ill write a full report on the new combo. There are a couple of youtube videos of Mark and I. He is using the gopro on his helmet but everyonce in a while you see me staying with him even in the worst of the mud.
Its Markdgb channel on youtube.

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ill have 2 look thoes up on youtube an check it out .. but if ya can email me some riding pics it would be cool ...

Wow sorry to here about your chain !! I can go from 12t to a 14t with the same chain just by adjusting it at the axle

I couldnt with the new chain. With the old chain i could but i ground out the rivets on the old chain

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maybe I dont have enough adjustment in the axle?? It was very hard to turn. should i disassemble the rear?