Don't know what I was so worked up about... Installing the new mains was easy. Too bad they were the wrong size. Rods too. Should've got bearings for .020" cut rod and main journals. The ".020" stamped on the back of the center main should've clued me in. (It did but I swore I'd measured them right... ) Now that I'm not measuring like an idiot... I hope... I've got 2.980" on the mains and 2.290" on the rods.
If I'm doing that, I'm starting on another short block. I'm not willing to put that much work into this engine at this stage. This is a last-ditch effort to save it. Unless it results in a miracle, the idea is just to get it on the road so I can build another one up right instead of being in a mad rush.
Ok, I think it's fixed! Got all the bearings in, buttoned it up and went for a drive. It's brutally hot outside so it didn't take long at all to warm it up. In fact, idling in traffic with the AC on, it got hotter than it should have. Even after a good 20 minute drive reaching temps of up to 230, the oil pressure never got lower than 22 PSI @ 500 RPM. Pretty good I think. Got 60 pounds cruising around warm, 50 hot, and about 70 at cold start. No more knocking or ticking! Hopefully it stays that way. Thanks a lot for all the help. If you guys hadn't once again given me great information, I'd still have that engine in pieces on a stand and it would probably stay there for a year. Now, I think I'm going to have to go back to a mechanical fan so I can drive it in the day. This Escort fan is clearly not sufficient anymore.