Hello Jet Boat Fans,

I am new to the forum.  I'm hoping to get some help with my problem child.  This boat has been my never ending project.  I applied mostly new gel coat (except the deck flake), new wiring, underwater led lights, floor, stringers, reconditioned all aluminum and polished, and started on the interior. 

Before I can fix the interior I need to get my mechanicals sorted.  The motor is the original 1976 Olds 455-4 Berkeley Pack-a-Jet.  I've done a cosmetic restoration on the engine, installed a new Edelbrock Performer intake, Pertronics marine HEI disti, and polished the sand cast Berkeley logs.

My problems with this engine are many.  I'll start with intake manifold sealing issues first.  I am using Mondello gaskets, heat riser block off plates, Mondello valley tray, and Street Demon 750 carb (converted to marine).  My problem is getting the front and back of the block to seal with the manifold.  Using these gaskets I am seeing about a 1/4" gap between the top of the front/back of the block and the bottom of the intake.  I thought I had a really thick bead of Ultra Black RTV there.  At idle it was fine.  When I cruised and did a couple 40-50 mph bursts it leaked lots of oil all over the front and back of the motor.  I was having this same problem, although not as bad, with the orig intake manifold too.  I am not using gaskets at the front/back of the block.

Any tips on a leak free install would be greatly appreciated.