Ernie,
That roller is a mess. You are fortunate that you didn't have more problems, but I think you are right about the engine having been neglected and that .040 lash being the start of the problem. I know there are many arguments both for and against roller lifters and I stayed with the flat tappet as the engine builder that did mine said he just doesn't like to put them in engines that are mostly going to be street driven. His statement was he gets the race engines back after a few races to go completely through and he finds some signs of damage even on them. After much discussen in 96 with the engine builedr in Ohio that built my stroker, he suggested I go with roller rockers and Hi Performance hydraulic lifters that are good up to 7500 RPM. Since my engine makes its power between 5800 and 6200 I don't have to worry about valve lash adjustment with the hydraulics and I have turned them 7000 a time or two. Have to get the rev limiter set to around 6300. But you will get more power with the solids, and that is what you are looking for. Hope that you have the beast running soon.
Ron
