Thanks all.
Total on this motor was ~40-50 dyno pulls, ~100 street miles, and 12 passes at the track.
I think it was a casting/metallurgy flaw, or #4 was simply the weakest of the bunch and failed first. Either the skirt developed a crack and then it fell apart, or the pin boss area wasn't strong enough and the piston came apart there, detaching itself from the rod. We heard it rattling after the burnout right before the last pass, but I ran it anyway and shouldn't have. It would've saved a lot of damage.
I'm guessing that the high rpm was the killer. We had the rev limiter at 9600rpm. Last years build never saw over 9100rpm, and lasted forever.
We knew what we were getting into by pushing things this far, I just didn't expect it to let go this soon. But we learned a lot and everyone can benefit from it.
It would have been really cool to get a few passes in at high boost with the new slicks and tranny before she let go though!
The 6 passes to license were nothing spectacular. I just wanted to get the licensing passes done before really pushing it, so all these runs were on only 23-24psi of boost with super worn out slicks (almost 60 passes on them), and normal lift shifting. Conservative passes if you will. We have new slicks to put on the car too!
All runs were 1.6 60's, first 3 were partial runs.
Run 4 also a partial run, 10.66 @ 118mph.
Run 5 was 10.5 @ 138mph, banging off limiter all through 1st and 2nd, short shifting 3rd at 8900rpm.
Run 6 was the quickest run yet but then I missed 3rd gear and went 11.0 @ 130mph.
They still gave me my license though because the missed gear was the only reason for the low mph, and they have seen the car trap over 135mph several times before.
Basically, the car would've went ~10.4 @ 140mph @ 23-24psi had it not come apart.
I'm still halfway tempted to just throw another vitara block together to run (w/a lower revlimit) while we are building the sleeved block.