David,
Thanks for the insight:
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the exact same Canton road race pan
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Actually, I think I have a different pan. If you'll note my info, my cars use 385 series engines, not small-blocks, so the pans could be quite different.
I have spoken to Canton at the PRI show more than once about the 385 series pan and they said they had no test data so if it doesn't work, well, it doesn't work...
So maybe it works OK on the small-block but not on the big block? I have heard from other 385 racers who won't use the Canton pans for the same reason; perhaps Canton's other pans are better.
Not sure I'd risk an engine after my experiences. Certainly not a 385.
Tom