Thanks a lot man, hopefully this will work. Do you think the problem with the car spitting coolant out of the housing-to-intake mating surface has anything to do with the fact that theres air in the system? I'm going to remount the housing today, let it sit overnight and let the gasket maker fully set, then burp it tomorrow morning. If you have any other info that might help me, that would be awesome, thanks!
Well Michael, as Grady just informed us
As he brought up, do you have a chrome water neck? Some have sanded the chrome down in all the right spots to make them not leak (I think Andy - Rio5.0 had some luck with this). If this applies, dont use power tools to sand it (or if you do, be real careful - chrome embeds in your skin real nice when you sand or grind it off).
Air in the system cannot cause leaks like that.
I cant think of anything else that it could be.
Good luck man!