Dave,
I understand your desire to have all your stuff "done right"-no cutting corners. But he's my experience.
The block sealant tabs really work and should not be considered a band-aid:
http://paceperformance.com/index.asp...D&ProdID=30363
That's why these have an OE brand name-they go right in on the assembly line of nearly every motor (especially aluminum) built. That's why the pros you consulted recommended them.
I watched them go into 30+ street/race engines per month, dynoed daily, from 300 to 1100 HP. The castings always had some issues, mostly all minor, and these were the solution. Of course a major machine error or crack was repaired.
On pressure testing-100psi may CAUSE you a problem. I've seen the usual testing was between 40 to 50 psi.
On a Dove, you may blow it sky high at 100-I can say that because I have your same TW. Since your cooling system makes maybe 22psi max, a 50psi test is plenty of margin.
If you must coat the passage, all your choices are effective, but if you PT at 100psi, you may go right through any coating if the underlying flaw in the manifold is bad enough.
Drive it and enjoy it-you've got a ton of work and $$ in it and Barry's great carbs...
