Audi 6a 2.0 Piston Clearance Issue?

I have taken a 6A block and KR head to a local engine builder for them to check.

They called this morning and that the pistons where .4000 (thousands) out when they should only be .1000 (thousands) out.

He said that if I was to do a proper job, I would replace the pistons at a cost of £60 per piston + VAT.

I explained that I wouldnt be racing this car or thrashing the engine and so would it make a difference.  He said not, but I would just have to wait for my engine to warm up before putting my foot down.

Has anybody else had an issue like this?  What should I do?

4 thou of clearance is a lot, when you consider that a forged racing piston might run up to about 3.5 thou and itll clack like hell at cold start until its warmed up and expanded to fit the bore.

To be honest, youre just going to end up building a grenade as the skirts on cast pistons dont like to be exposed to large clearances, itll hammer them to bits hot and cold.

Bore and hone to next available size and replace the pistons is your best bet, at least the piston to bore clearances will be right and itll last.
Trying to run it with 4 thou of clearance is asking for trouble in the form of cracked skirts, low compression as the ring end gaps will be way wider than optimal, poor oil control etc.
The reason you have 4 thou instead of 1 though clearance is because the bores and pistons are worn out.

Thanks for the detailed response.  I think I need a new block or new pistons in that case.

My next queston is, would it be cheaper to buy a new block or get new pistons?  They told me the pistons would be £60 + each.  If that is the case I may as well save a little hard and get forged and turbo the bloody thing.

Well no need to replace the block if all else is in fine fettle, pistons at 240 quid for 4 and then a bore and hone at 150 or less and youll be into a decent starting point, unless of course you can find a good used motor for the same amount.