Well, i'm in the process of trying to figure out exactly what happened. Comparing the cylinder bore to the piston size I'm getting .004 to .005 clearance on all cylinders. The odd thing is that the cylinder with slap is .004, and all the rest are .005. I'm going to take a closer look at the bore to make sure it is uniform.
Talked to Ted at engnbldr, and he said they usually set up for .0015 to .002 clearance. He said my clearances would probably be ok, but that was just a little on the sloppy side.
I'm wondering if this could have been caused by something else. Like running rich on one cylinder. I had alot of black resin carbon buildup in my upper intake, throttle body, top of the pistons, etc. That just dont seem right sense I cleaned all that stuff when I installed the engine 25K ago.
