Frank, normally the piston "size" stamped into the dome of the piston is actually the bore size, and whatever clearance the piston's manufacturer wishes to have is built into the piston by reducing the OD of the piston. As an example, if the piston manufacturer wanted 0.001 clearance, the piston would be 4.039 diameter, giving it a 0.001 clearance in an 4.040 bore.
Larry ... 0.085" on the major thrust walls?!
Are you sure you're not quoting the "non-thrust" figure?
To both of you gentlemen, I'd take the block back to 4.000 with dry sleeves before I settled for 0.085" thrust walls. In fact I'd install dry sleeves before opting for 4.040 pistons. Or I'd purchase a set of forged 4.030 pistons and live with a little bit of taper. Done that many of times.
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