Yeah, I would try just honing the cylinders then, but it wouldn't hurt to have someone measure the bores just in case. I had an engine that I though looked very good, but was worn and needed to be bored out. If you take the head off at least go that far and if you do put pistons then look at the bearings too and replace them if necessary.
As far as that one cylinder never looking like it was firing, sometimes when there is a coolant leak in the cylinder it cleans the top of the piston and makes it look like it never fired.
Just my 2 cents
Russ
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