Originally Posted by planemanx15
My theory is that since I didn't do the ring gaps, they expanded with the heat and pressure and scoured the cylinder and piston. This created some free play and the noise that was heard was the piston not seated properly.
Any other opinions would be appreciated.
One last thing... Remember that the metal that used to be part of your piston skirt is now somewhere in the engine. I would check the crank and connecting rod bearings very carefully by rotating them by hand to sense any roughness. Remove the oil filter and cut it apart; hopefully you'll see evidence of the metal trapped there. Drain the oil and see if you see silvery bits of aluminum, then flush things out as best as you can. The oil cooler would also be a good candidate for a flush.