Well, what bothers me is that this motor was never sounded like this. Last year when we all ran that trip it was great shape, no knocks ect. I doubt it is the cast... The knock is it's worse at start up. Once the oil gets circulating it takes the noise down some. If I had a little more cash I would just take it to Curtis. I shoud have some news this weekend.
you should plastic gage your rod bearings i know you got a short block on it last year but my buddies just did the same thing and it was a rod bearing.