Hello,

If anything, the clicking means you have good clearance. I went through a lot of pistons and sleeves (normal wear) but never a rod on BVM 82, 91R or the 96.

I would guess the clearance should be about 0.003 in, Col Thacker showed me an old trick, that is about the thickness of a page of a magazine.

I would not drill anything or modify anything but of course that is your choice. And start looking for spare pistons and sleeves!