1.9 jacket reseal . . . or not after overheating

[jfu057]

Hello samba and thanks for all of the help so far (via the search).

I have a early vanagon (named wembley) with 1.9 wbx that suffered a low coolant overheating episode (the "in a tunnel under the bay" kind). This resulted in white vapor and droplets out of the tailpipe and a multi-state flatbed trip. Before the flat bed I performed a compression test (didn't have a leak-down kit), which resulted in cylinder 1 having 25lbs(140) less than the rest. All other cylinders were right around 165. There was no mixing of fluids in the block, just coolant in the exhaust (just...), and it seemed to run normally (other than the obvious exhaust water). For some reason this all seemed promising to me...

By the time him got home, there was water pouring out of the tailpipe when I started it up to pull it off of the truck. When I pulled the heads, the number one cylinder looked to have been steam cleaned.

Fast forward through a month of researching this fine website, learning how to disassemble my first vanagon, and ordering parts. I had the heads pressure checked and the valve seats and seals recut by a local machine shop, pulled the engine, did my best to clean it up, crudely inspected the cylinders and pistons (seemed okay with a straight edge), cleaned all the sealing surfaces, and reassembled. All of this went rather smoothly

which brings us to now

I got it started up yesterday and there is again white vapor and droplets coming from the tailpipe and a visible spattering of coolant coming out around the exhaust manifold of the #2 cylinder (originally I believed the #1 was the culprit). so now to the question...

wtf?

no really, the question is does it sound like the cylinder is warped in this case? or did I just miss something? I assume that if they were cracked i'd have coolant mixing in the oil.

I'm going to do another compression test and probably order new jugs and pistons, just wanted to get some advice beforehand. Is there somewhere else I should be looking?

to recap:
1. overheated
2. coolant flowing out of tailpipe
3. zero mixing of coolant and oil
4. compression #1 145, #2-4 165
5. post reseal, still coolant in the exhaust seemingly from #2.

Thanks!
-Frank