it leaks..... :(

[289fia_cobra]

Ron, before I even read your post, I proceeded to look at all 6 bolts (essentially those around the ports) and as you allude to, ALL of my bolts were loose. My leak was a puddle, not just a few drops.

I used a 3/4 torque wrench and had everything torqued to 14.5 ft-lbs. Ford say 12-14 but since the gasket is swollen, I figured a 1/2 lb. would help squeeze them back. All of my bolts are SS, not carbon steel so hopefully they aren't as brittle as to snap with just an extra half-pound. But yes, the lightest was like 6 lbs!

As a 2nd pass, I used my digitial torque reader and went over all the bolts one more time because I know my wrench is about 1/2 to 1 lb. off.

I drove it around for 30 minutes so it would get to temp. Got home, and for the first time since I rebuilt the top end, the overflow tank indicator tube rose 3" just like it used to before this all started! My cooling system FINALLY pressurized properly. This morning it sucked it back in to the normal level and not a drop anywhere.

I'm probably going to start doing good re-torque every season.