351C FelPro Intake Galley Pan gasket not fitting

Nothing seems wrong from your description. The pans do have a slightly different angle shape than the engine parts. They have to be pushed onto the dowels in the heads. I noticed that the same was true of the metal intake pan on my 400 when I replaced that.

Some people like to modify the pans rather than installing them as-is. Sometimes the intake areas are a little difficult to make seal, so some people eliminate them. After reading what other people have done I cut the intake port portion of the pan off and then drilled a hole in the lowest area of the pan so any oil that gets in there can drain. Then I just used one set of paper gaskets on the intake. On the valley pan rails I mocked everything up first to determine how much thickness I needed, and put down beads of silicone under and over the metal pan. I let the silicone set up for a while before dropping the intake on.

I tried to post a photo but it didn't work for me. Here's a photobucket link:
http://s1204.beta.photobucket.com/u...rt=3&o=0&_suid=135377643551406248929750902676

Yeah bending a lot sounds wrong to me. What I've seen on the metal pans I've had is the bends are short, so it's a little flatter than it should be. On my 400 I just pushed it into place onto the dowels that fit into the heads and those dowels kept it in position while I put the silicone around all the ports and on the valley end rails. On the 400 it seemed to seal up fine and work ok.

Can you show us some pics of what you mean? I just installed that gasket in two motors- one a 2v and another on a 4v. Didn't seem too hard. Show us what your dealing with and maybe we can get a better picture.