Opps, I forgot to mention that I pressure tested and it is golden. Not a drop at all in both pressure and vac tests. I almost think it was something to do with the fit of the piston. It never felt quite right even when brand new (Meteor piston on a 036 cylinder, which had never been cleaned up). I got the saw from Wes (scored 034 with torn intake boot) and made it into a 036. So I'm thinking cold seize (highly doubt it) or piston fit problems. Everything else looks and tests out to be fine.
Did you check the ring end gap and skirt-to-cylinder clearance prior? I haven't had a failure yet in the 20 or so Meteor pistons I've used. I did a side-by-side comparison in a 460 with a new Meteor piston and a new Stihl piston. All measurements were exactly the same. Fit in the bore and skirt clearance was the same for both pistons as was the ring end gap.
I still gotta tear it down a little more. Lots of "rigged" nuts and bolts... Also the plug wire is cracked and frayed... can a new one be installed/spliced on the ignition?
I have yet to even pull the ignition system off and even look at it.
Gary
Those ignition leads are epoxied in...I have extra ignitions so you're welcome to one.