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Are you sure it is the powerhead?? Sometimes those rewind pulleys get sloppy and bang/rattle around… You had the powerhead apart and put a new piston in it…Did you bore it oversize, or just hone it? Is it possible that you honed too much, actually boring the cylinder oversize a bit? Did you have the crank out? If so, did the lower needle bearing look OK? These get rusted pretty easily, and usually fall apart when removed from the crankshaft. What does the noise sound like to you? Just it sound like rusty/worn bearings, or does it sound like piston slop? I suppose it is possible that the gearcase is torn up making the noise you are hearing as well…Was the gear lube OK when you changed it?
Back to my original thought. Try removing the recoil and wrapping a rope around the flywheel to start it, see if the noise goes away…
Any chance you could post a video of the engine running?