I have a gen 5 8.2 block with a bad cyl that is already 4.530 and a gen 6 with a "sloppy" 5.30 bore. Do they make a 4.540 piston that will work with a 6.135 rod? I've run out of money and want to see the water some one this year. Both are production blocks. Suggestions?

Call Diamond Pistons they modify self stock pistons for a fee.

how about sleeving that cylinder?

+1

Machinist was saying about the distortion in adjacent cylinders. After honing would likely give me too much piston to wall clearance. I would like to just go to a 4.560 piston but I'm told in on the production gen 5's and 6's that its ill advised for a marine application.

Yes sleeve it

Why not pick up a used block. All of that machine work is going to cost a lot of coin. I can't believe a used block bored to wherever you want it to be would not be cheaper?

i know you don't want to hear this but the smart play is to fix it right the first time regardless of cost. if that means not getting in the water then thats what it means. in 100 out of 100 cases trying to shortball a structural repair because you are short on cash ALWAYS , as in " every single time" ends up costing you more in cash and considerable aggravation later on when it fails prematurely and either ruins something else or just requires you to do it all a second time. i am not suggesting you can't make what you have work , one way or the other,.. of course you can. i am just suggessting that you don't make the same mistake that lots and lots of other people desperate to get on the water make...

Respectable answer, question is.. What's the correct fix? New blocks, new pistons, sleeving etc?

I was told a gen5 or 6 502 is a Siamese bore and sleeving one hole will cause distortion issues with cylinders on each side.