I'm traveling, so this update will be brief.
Another good news / bad news day. Good news: TSP says they can clean up the cylinder with just a 0.005" bore! I'm really surprised by this, but they are confident they can do it. So I can utilize my existing LS2 block. YAY!
Bad news: when they completed the tear down, the main and rod journals have been scuffed by something in the oil. That's going to mean turning the crank. But to add insult to injury, this crank, which was supposedly new, has already had the mains turned 0.010"!
Now the real kicker. TSP doesn't turn cranks, and they don't know anyone in Austin that they trust to turn this one. It's a Callies DragonSlayer which is supposedly hardened after being cut. I think they really don't want to trust having a shop turn a pricier crank like this. So they want to send it back to Callies to do it. The problem there is that it could take 3 weeks or so to get that done. I'm waiting for a call back to confirm that turnaround time...
I'm going to have them replace the oil pump also during this rebuild. I actually don't want the high volume pump in there it currently has, so we are going to use the Melling high pressure pump instead. I won't have a choice in that now after this discovery, so it's good that I was already planning on that...
It will be interesting to see if there is any damage to the cam journals. He didn't mention it, but I am planning to replace the cam anyway...