Mike,
As previously stated by someone else, please keep in mind that boring .040 over is NOT normally a good thing for our Cleveland blocks. Keeping the .040 popup pistons will of course require punching the "donor" block to that same size which could be counter-productive.
I would say that a better decision might be to try and find a standard bore block and clean it up to the minimum bore size you need and order custom pistons for the desired compression ratio, utilizing the chamber volume on your open chamber heads. I believe you will come out "cheaper" in the long run.
I am honestly intrigued by what you actually have with that motor, what with all the (on the surface) mixed and matched parts. Quite frankly, if it was me, I would tear it all the way down and see what crankshaft, what camshaft and everything else that it has. It seems to me that someone has definitely been "into" that motor.
BT
The motor has been rebuilt for sure. Since the heads are from different years and there appears to be only one over bored cylinder, we think someone sucked a valve and scored the cylinder in question while also wrecking the head. The head labeled D3 on my '71 is above the broken cylinder. The story begins to come together. If they used a larger piston on cylinder four, how did they compensate for the weight imbalance? We also noticed the head gaskets were different between right and left. By that I mean of a different material. When we thought we only had a blown head gasket, we looked at three different gaskets and only one set fit properly although all three were made for a 351C 4V engine. We will for sure pull everything from the broken block. Whether we buy a short block or a simple block and use the parts we have remains to be seen.
mike
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Yes, Mike I am EXTREMELY curious as to what else is inside that motor, particularly the other 7 pistons.
Considering how well you say your Mustang ran, I (like markmel stated or inferred) am wondering about how it was balanced, what with the one over sized piston.
This is a "head scratcher."
BT