UPDATE:
Installed (1) new piston and (1) rod from ford, put the engine back in and started right up with a loud knock coming from the #6 cylinder (the parts i just replaced). so i take the engine back out and measure the piston and it turns out the reman engine was bored 50mm oversize and ford sold me a standard piston now i go back to ford PISSED OFF because i gave the ****** the old piston to match up, they refund the money for the wrong piston and tell me they cant get the correct one. So i go back to The machine shop i used to press the pin on the rod and start looking for (1) 50mm oversize piston and luckily we find someone who has in stock, put everything back together last week and installed the engine over the weekend and it started right up and runs perfect. So too answer my own question.....YES you can replace the (1) bad rod and piston as long as you carefully inspect the rest of the engine and measure your parts before you install ...not after like i did !
50mm is almost 2 INCHES! Rather a large over-bore, I'd say. 5mm is a bit under 0.200", that's
possible, but not likely, because it would mean you stuck a piston in a cylinder which was nearly a quarter-inch too small. No way you could have done that. So, maybe 0.5mm? 0.020", twenty-thousandths of an inch, still a pretty sloppy piston fit, but possible to miss by eyeballing. So you ran an engine with a piston loose by 0.020", very possible. Piston "slap" must have been pretty amazing. You have gone through a lot of trouble, give you credit for sticking with it. Next time, beg, borrow, steal, or buy a couple of measuring tools, like inside and outside micrometers to check parts fit before buttoning things up.
Glad this turned out OK for you, and that you let us know. Been 6 months or so, but I recalled the discussion.
QUESTION: During the time the damaged piston/rod was on its compression stroke and bending the rod, it should not have been possible for another piston to be in a closed valve full(water)cylinder because one of the valves would always be partially open or the piston would be on the down stroke, is this correct?
@PunziRacing 6-cyl. eng. gets a compression stroke in some cylinder every 120 degrees of crank rotation, (I think!). Judging by the "buckle" in the damaged rod, a guess would be that the "slug" of water sealed in that cylinder was less than 1" thick, so the piston was pretty near the top, minus an inch. Next cyl. getting ready to fire would be just a bit more than 120 degrees away, say 150. Even then, it's intake valve would have already been closed, and it was starting upwards on compression, so, yes, water might have been in the next cyl. ready to fire. BUT, even if it was ready to smash another rod, the one being mashed stopped the crankshaft pretty abruptly, would be my guess. But before the next slug of water squeezed? Who the hell knows? How fast can a revving engine be stopped, without breaking something in two? Wish I knew. I am guessing the amount of power needed to stop all that spinning mass in less than one crank rotation would be incredibly high, enough to break the block in half.
If my analysis here sounds wrong, please tell me! This sort of technical **** intrigues me! imp