Terry, I find it hard to believe that as meticulous as you are with your motors, (measurements etc) .. that something like this would escape your eyes!! I still think you are dealing with a lubrication issue of some type.
After the second crank, I'm pretty sure that a bad rod would have shown up in other ways that you would have caught. No?
Scoring, burn marks, bluing, out of round, bending, thrust loading marks elsewhere in the motor...it's hard to believe that other parts associated with the damage showing up on the crank haven't been seen on themselves... like the needles, rod big end issues etc...