440 overheats once and then it's happy all day

I had to do some "porting" on my 440source water pump housing to make the port areas more consistent. I'm using the pass side lower hose outlet. The biggest problem I found was the water flow inlet/outlet holes in the casting are not lined up with the engine block holes. I had 1/16 inch of gasket separating inlet from outlet on the drivers side, rather than the 1/4+ inch as on the engine block.

I glued the gaskets to the housing, then lightly coated with blue rtv and bolted overnite to the engine block...this clearly showed the passageway misalignment.

I egged out the bolt holes to shift the casting (down if I remember right). This did not help as much as I had hoped. I'm going to try it and see how it works. My back up is an oem cast iron housing.
I wanted the alum weight savings, but for pass side hose there are limited choices, and the 440S casting would have been great if they bothered to make the mold properly...at least correct the mold before going into production. Where I work these mistakes would not be tolerated, instead demoted or out the door you go.