Hey Doug. Yes sir, I plugged all the holes with shop towels and between brake cleaner, a shop vac, and more shop towels, it was literally clean enough to eat off of.
So this is how it went today. As stated above, even though I had it clean yesterday and prepped to go, I gave it an additional once over just to be sure. After about 10 minutes, I began by coating the bottom side of the gaskets with TA-31. Light but total coverage on the whole surface, but with extra coverage around each water jacket. In putting an additional bead around each water jacket area, I would then lightly run my finger in circles around it to make sure that the TA-31 had even and full coverage. After this, I placed it onto the head and lightly pressed down all around each intake as well as the water jackets. I was sure that I had good coverage around the water jackets because when I pressed all around, I began to see the TA-31 squish out slightly. Luckily it squished out evenly and completely all the way around, so I was sure it would seal (at this point). Then on to the other side in the exact same way. Finally, as placing the head gaskets took about 5 minutes each, I spent the next 10 minutes taking an exacto knife and evenly cutting the wedged shape cork ends off of the rail gaskets. After I had each one nipped off, I covered them all the way around with TA-31 and pushed them under the corners of each head where they over hang on the block rails. At this point, the intake gaskets had been sitting for about 10-15 minutes and were on pretty well. I then covered the top side in the exact same manner as the bottoms (paying extra attention with the TA-31 to the water jacket areas).
Finallly, I ran a "generous" bead of TA-31 all the way across the back rail as well as the front rail (to be clear, there is now no cord gasket on the rails with the exceptions of a cork wedge at each corner. With help this time, I placed the intake manifold down slowly into position. Jay gave some advise as to make sure the distributor is installed and centered before bolting it all down. With the Distributor in, and seated evenly, I placed 1 bolt on each side just to get started (not tightening them down, but just getting them started). It was at this point, I wanted to check and make sure everything was OK before finally bolting the intake down for good. Upon inspection, front looked good, however when I got to the back, I saw that one of the triangle cork gaskets was pushing out! I tried to push it back in, but with no luck. With quite a bit of frustration, I realized I would have to pull the intake off to replace the cork wedge. As soon as I pulled the intake, I realized I would need to "touch up" the intake gasket especially on the rails and the water jackets. So I did just that. I put an additional bead around each water jacket and using my finger made clockwise circles to ensure it was even. I then put an additional bead across both the Front and Rear rail. Finally I put the intake back down and bolted it all into place. Feeling like it could have gone better, I decided to try running additional TA-31 on the back mating surface (where the intake sits on the rail). I would put a dab on my index finger and run it back and forth to make sure if even there was the tiniest gap or pin hole, that I would have filled it in before the gasket becomes hardened and oily after the first run.
On a positive note, The intake lined up perfectly with the bolt holes (both times) and the distributor fell into place quite easily and is all lined up with the marker lines I drew to mark the timing.
I have not yet installed the throttle bodies as I wanted to let it "breath from the inside too for maximum drying of the TA-31. I am not sure if this is necessary, and I am also not sure how long I should wait before it is sure to dry. I was going to give it until Sunday or Monday and then reinstall the Throttle bodies, Fuel lines and wire harness.
If this works and has no leaks (Please GOD let there be no leaks), I would say that my mistake the first time I re-did the gaskets would have been the prep. I cleaned it 200% better and cleaner this go around, so hopefully this works.
I don't know why this car fights me every step of the way. LOL Fingers Crossed
