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Where did you check your ring gaps? at the very top or bottom? middle? all three?
And what were they set at?
One more thing, have you fitted a piston in the bore and checked for tightness?
Does it scrape(or a lot of friction) mid-stroke?
Do this with no rings in it, to narrow it down.
Did your machinist have the pistons when the block was being machined?
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