If i was you after having trouble in the past (which i must admit looks like other peoples poor work) i would be taking that engine out and dropping it off at a GOOD engine builder.
I wouldnt bother with self honing, no self measuring, gapping & fitting pistons & rings yourself, get that thing cleaned & measured professionally, they will check bore and block measurments, ensure your crank journals all measure up and fitted correctly with pefect float etc etc - it will last an age if done right and not pushed past spec.
Get them to do the head too & time that thing up while your there, you know it will be right then, no funny valve problems or crap to try and get to the bottom of.
Save the heartache if something else goes wrong - I really like what your doing but it seems like you have had nothing but a sh*t fight since you had your 
ibiza, it would do my head in.
 
Save that BT money for a good engine, the labour is expensive but thats for a reason.
Rick