Bad news. The 440 is dead!
I knew about the chunk missing from the bottom of the bore:
The chunk is about 1/2" high and a little over an inch wide. I wasn't too worried since it is below the water jacket but I wanted the machinist to have his say on it. As he looked closer, he saw THIS:
I never noticed the crack in the cylinder.
The engine never overheated after the rod broke. No oil in the water but then again, there was no combustion in that cylinder after the piston stopped moving. The piston was an inch below deck when I pulled the head off. It may have blocked the crack off.
I could sleeve the cylinder but it is not a rare block. It is a 1976 casting from a police car. I have that other 1970 casting 440 to use if I need it.
I've joked for years that the motor was cursed and maybe it is. Check this out...
When I decided to rebuild it, my regular machinist had quit his gig and was nowhere to be found. I had to find another shop.
During the pre-oil, I couldn't get pressure to build. I tried 2 other oil pumps before finding a missing gallery plug.
While trying to slowly turn the engine over by pulling on the drive belts, a buddy bumped the starter solenoid and trapped my right hand in the crank pulley by the 2 fan belts.
It was hard to get it to fire for the break-in.
There was more valvetrain noise than I'd heard from a hydraulic cam setup.
At 846 miles, it broke the #4 rod but still ran.
I pulled the engine and built another but used the "new" Edelbrock heads, valvetrain (Stock from the '76 Cop car) and intake.
The right side rocker arm broke when on a drive with the next engine. On the way home limping, the rebuilt trans started acting up. After replacing the cam/lifters, pushrods and all rocker arms and shafts, the trans gave up.
Now the cylinder has a crack in it. Maybe that is a GOOD thing. Who needs more bad luck ??