Something does not add up here. Those pistons should really not be much more than .020 down in the hole. They are zero deck with 5.7 rods....if your block has a deck height of 9.005 inches, but that is pretty rare. Most production small blocks are in the 9.025 range, which means you should have had to cut about .025 off the decks to get zero deck. We have rarely had to cut .040 off a small block deck. I have to wonder if the crankshaft was ground with the stroke slightly off ?? You might want to check it, although it is hard to do without a long travel dial indicator. A slightly short stroke, combined with rods that had a lot cut off of them to resize the big ends, could add up enough to cause your problem. Did you check more than 1 cylinder to see if they are all the same ?
I hate to say this, but I am going to because I love to rub it in..
..If you had purchased the parts from your machine shop instead of the "mail order" place, you would have known all this to begin with. It might have cost a bit more at first, but it would have been right. At least they could have measured everything and told you that you were going to have to deck the block. Just had to get in some friendly ribbing of the mail order guys.
Looks like your only choice at this point is to deck the block, which will mean intake alignment problems. You might want to mock it all up when you are done and have the intake surface of the cylinder heads machined to compensate. Otherwise you will have to mill the intake and then it will only be good for that motor
Let us know how you make out,
Advanced Automotive Machine
1971 Chevelle "Heavy Chevy" original owner
1973 Z-28 ..one family car...Brother bought it new in 73
[This message has been edited by BillK (edited 04-10-2001).]