TODAY'S UPDATE: I took the block and pistons into Portland Engine Rebuilders today and told them they needed to hone to .0045. I explained that it all seems to have come down to the issue of the sleeves not transferring heat like a simple bore of the block, combined with the already questionable water distribution in the block. They posited the idea that the overheating may never be solved because of the sleeves. I've sleeved one other engine back to standard, and the builder claims he set the piston clearance at .003. That engine has never locked up, broke in like normal, and runs great.
At this point I am out of options. I'm going with the .0045, new rings, clean block, and new radiator, and if that doesn't solve this, I'm done.
ORIGINAL POST: I posted this over on the VFF, but some guys here don't read that forum, so I put this to the Barn:
This engine, with only 4000 miles on it since rebuild, has always overheated and locked up when shut down after overheating, which is usually when driven at 45 or less for 30 minutes or more. (This did not and does not happen when driven under 35 and/or just around town for less than 45 minutes). I thought I had this problem fixed. But apparently not.
Here is the history: On 3/16/14 I installed an engine which had been boiled out, sleeved back to standard, new pistons and rings from Snyder's, new valves, exhaust valve seats, new lifters, and new babbit by Bill Barlow. It was tight, but I figured it would loosen up during breakin, which I did very carefully, as I have done with all my previous engines.
After 2000 miles it was still overheating and locking up on shutdown. I took it apart to check measurements. Ring gap, rod bearings, and piston clearance were just where they should be, according tbirdtbird, Bill Barlow, Tom Godish, and several other commenters on the Barn. But when reassembled it had the same troubles.
Thanks for indulging my long post.