512 Cylinder liner

you may take a small flexible grinding and cut the edge. I would not be worry about this so much

that I would worry about. because that is a typical sign of light piston "eater" ?? or short piston blockade. also you may look at the rings. I´m sure that they are also damaged a little. take a magnifying glass and you will be shocked when you see it

it would be easier to warm the block a little. best for this is a large pizza oven. don´t take a flame because the block has to be warmed completely. also you need a special tool for putting out the sleeves.

you write here that there are still the cross hatching visible? normaly when I see those piston shafts the sleeves are also not ok anymore. but may be only a short blockade of the piston has happened. for example when you accelerate hard in cold condition.

if you want to do it perfect you may put in 12 new sleevs and 12 new pistons.
if all pistons look like this one here I would take new ones

if you like to do it best as a compromise between cost and technic I would meassure all sleeves, when they are ok let them in. meassure all pistons, when they are also ok let them in but use new rings.

 

Might want to consider boring out the cylinders & having custom pistons made vs the cost of removing old sleeves & pressing in all new sleeves.

 

Makes me wonder, what would cause that to break off?

Ago

 

Did you find the pieces of the chips inside the crankcase?

 

I had the same issue, 1.5mm overbore and had Carobu make up some pistons ( 10:5)
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May I suggest you perform the necessary checks of the bores prior to worrying about the pistons. Have the bores measured well for any hour-glassing and appropriate diameters all through the bore. If they do not measure within spec they will have to be overbored and new pistons will be required to fit the new bore. I would absolutely replace the chipped sleeve as well. That said, In the event that all liners measure within acceptable tolerances I would still order new forged pistons with a slight bump in compression as technology had come a long way and IMO it makes no sense reusing many of those old pistons or locating good used somewhere.