Jan - thanks.
I have a couple feelers out on replacement blocks, will see how that goes.
Also will take Air-Pine's banged up block, along with the part's car block, to a local machine shop for a review.
I don't know the first thing about blocks at this level of detail. One block is early, and banged up. The other is very late, and has its pistons frozen to the cylinders. From what little I can tell, the later block/engine died from a cooked head.
Sleeving makes sense, from a long term perspective. The expense is a little scary. When I turn up a $number, I'll let folks know, in case others are interested in sleeving.
Jose - I hear you on the V6. Installing a V6 is an option I intend to pursue, but not on the Air-Pine. May be irrational but I've my mind set on it running Sunbeam under the bonnet. Something about the quirky Sunbeam engines got ahold of me.
Allan