[hamjet]

If you truely have .001 clearance it should not be too tight that it would prevent you from turning the engine over. a 250 ci engine calls for .0007 - .0027.. As stated, either the conn. rod is egg shaped or its the crank. Do try swapping around rods as stated to see if its the rod or crank. You say the crank was machined, what was it turned down to.. Good catch by the way...