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		With regards to the bent con-rod - wonder if it was a head gasket issue?  When my head gasket went due to plastic dowels failing, I used to park the car when it was hot (before issue was diagnosed) then after a while when I tried to start it, it would initially stall the starter motor (lock up), then next try would usually start ok.  I presume that on stopping, the over-presurised cooling system was forcing fluid back through the leak into the cylinder, causing a hydraulic lock?  What cylinder was the con-rod out of, and was more than one bent?  If it was the rear-most one I would suspect the cause I mention even more...
Good work by the way!
Dave
	 
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		Number 1 (front) was the (visibly) bent one on this one. It could well have been damaged from something like that. I don't think we will ever know!
	 
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		I rebuilt my TD5, I threw it away & put in a 4.6 V8 1/2 the price in the long run!!!  good luck
Jeff
	 
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		Another old post,but wondering after several years how the rebuild is going?