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Originally Posted by GMR5
Block is zero decked so my pistons should be .005 above the deck (9.005).
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Zero decking means to deck the block to where the piston deck clearance is zero. Not to where the pistons should be .005" above the deck. Based on what you've written it is hard to guess what your block is decked to. The blueprint dimension of the block is 9.025". Based on your dimensions, it is impossible to tell where the problem is, but more than likely it is in more than one place. Even if the crank doesn't have uniform strokes on all the journals, the #1 and #2, which share a journal, should have similar deck heights. They are different by .014" with the left side of the block being the highest. My first thought was that the block wasn't decked the same from bank to bank. But then I looked at the rear crank journal and the #7 deck is .003" lower than the right bank, the opposite direction of the front journal. You should do some careful checking of the block, the rod lengths, compression height of the pistons, and yes, the crank stroke too. Possibly by mixing and matching parts you can come up with acceptably uniform deck heights, but it is doubtful. A super thick head gasket would just be a band aid and negate the purpose of decking the block in the first place. You have some serious dimension checking (measuring) to do.
RACE ON!!!