Started the engine build yesterday, got some of the studs out of the old cases and installed in the cleaned ones, fitted the ball bearing on the drive side, swapped the scavenge pipes over, everything going along fine. Fitted the new -0.010" big end shells into the timing side con rod and torqued it up to 10 lb-ft no problems, the rod spins on the crank as smooth as silk. Fitted up the drive side the same and it's tight, checked and cleaned everything again, still tight. Removed the assembly from the timing side and fitted it to the drive side and it's fine, so the journal is OK, the problem must be in the rod itself or the cap. 5 hours spent trying to find the reason, and still not there. Start again this morning, if we can't find it then the rods and end caps will have to be ground on the mating faces and re-honed to size I reckon.
Still, if it was easy they'd let women and kids do it.