Hi,

Mark wrote:

" So we are back to: How do we keep this head area surrounding the water
jacket un-molested by coolant? My reasoning is that be gentle with the
motor until it is warm enough for the aluminum to expand and bring the
clamping force up to an operational value, then coolant will not be
force
beneath the seals. "

I vote for a nice smooth layer of JBWeld over the heads where the seals
sit. You can't keep the fluid from getting under the seals. Any gap will
let seepage occur, and clamping forces can simply curl up the edges.
That seal is not 100% backed up, rather it is a fat horseshoe shape with
just the mid part getting compressed, sides free to lift. So get a good
epoxy coating in there that won't corrode away. Once corrosion does
start the alum. oxide puffs up nicely and holds the seal off the head,
acelerating the process. Positive feedback.  bye, Tim