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VB,
Did you end up checking the 98.5mm depth between bottom of crankcase flange and top face? What was it on your barrels? What about the stroke - did that come to 82mm?
Occam's Razor - All things being equal, the simplest solution is usually the right one. If the barrel is a known standard Triumph barrel, the stroke is 82mm, and the pistons are non standard (which they look to be), then it's got to be the pistons.
What you could do from here:
Measure the height of the piston crown above the barrel top face.
Measure the depth of the combustion hollow in the head.
Check if the two will theoretically fit together - include the head gasket in calculation
Put the valves in the head without springs (wrap some tape around the stems so they don't fall through), and fit the head (gingerly - making sure you can get full crank rotation)
With pistons at TDC, check how far the valve stems will move before hitting the pistons. If this is shorter than the normal throw of the rockers (depends on cam), then you need to replace your pistons.
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Per Ardua Ad Astra
(Through difficulties to the stars)
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