Well, we had been worried we were stressing the block too much, and that the exhaust port crack was a 'stress' crack.
It was, but not because we were hammering the engine too hard! When we switched from head bolts to studs, it seemed like a great idea-still does. However, the studs were just a tad too long, and were tightened into the port, cracking it! So, the damage is self-induced!
We thought maybe this happened on the salt, but now know better-we never touched the drivers side studs, yet they are showing the same symptoms. this from Don:
I removed the heads and took a good look at area we cracked and you can see by
the picks we are lucky we did not do this to all the ports. These pics are from
the opposite side of the block we cracked look close you can see where the
studs jammed against the back side of the runners So, we'll write this down as a learning experience, and get the studs trimmed!. We also scored one cylinder. We won't know until we tear it all the way down if there was a ring issue, or if the water leakage possibly washed the oil away, causing the damage.
The roller lifter setup worked great, and looks great, but I'll let Don post that up!