Small block timing cover install problems?

I just had my cover off last year due to a water pump bolt snapping off in the block. I tightened ALL bolts then put damper on. Zero leaks, bone dry. If you look at the lower bolt holes the tolerance on them is very tight and that will align the cover. The seal/damper will not align the cover.

Agreed. Due to the problem you mention above I had also purchased a SS bolt kit from ARP and liquid tefloned the threads. Grooves worn in the damper seal surface will never seal which is why I always use a new damper on a new build. Fel-Pro also offers a kit with a new outer damper seal surface sleeve. Just food for thought.