Engine builders/Gurus, I need your help.

When you had the head off did you try rocking the piston at TDC.

No I did not.

How about a porous casting or hairline crack in here?

The heads that are currently being used are 440source aluminum. I wouldn't have thought to look there, what would the problem be? Could you please elaborate?

I did have a mystery tick on my father inlaws chev 350. Turned out to be a cracked flywheel...

I wouldn't think so, wouldn't the tick be much faster if this were the case? Same as a torque converter bolt coming loose. I'm not automatically dismissing this as a possibility, it just seems the tick is much too slow.