Well It Leaks AGAIN!

When he cracked the block did he notice it right away Dave?
Not that this is the problem, but I recall a member trying to install an expansion plug up above the rear main and it cracked his block. I believe he found it was the wrong size plug.

Supercharged I commend your persistence! Man what a frustrating journey for you. Hoping this is it!
I wonder when you install new plug if you should pull cam 1st so you dont risk hitting it? Just a thought, fingers crossed.