Monty thanks for replying to my post I am quite baffled myself. However i still love the engine and will buy another in a heartbeat. Going to try to save this one first. Got my eye on one of those X3's do you know if they will come in a prerun model. I hate break in and loved the fact that all had to do was drop the bf on the track and start running it.
Ray thank you as well I will check the engine for any toe nail clippings

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Could you elaborate on piston failure a little for me and when you said contamination that kind of rung a bell. I noticed that around the crank shaft front bearing end the it was like a dirty oil. Also there was oil around the front of the bearing (outer). I run the RB engine protector amain part# RBD02010-001 on my engines. It goes over the crank and rides between a shim and the flywheel cone:
front bearing,shim, engine protector, flywheel cone in that order.
It is supposed to help keep any dirt from getting into the front bearing. When I took it off there was no dirt however I did notice oil on the outside of the bearing.
Ray I know when it comes to piston and sleeve fit your the best. question for you should after a 1 1/2 gallons be zero resistance through the tdc stroke? Generally I have always noticed a slight resistance or pop we can call it through tdc even with no plug installed. for the most part with the head off when you spin the crank it will push the sleeve out some not the case here.