Brent,
I don't know if this will help, but about 4 years ago I had a similiar problem and kept getting just a little drop or so of water out after driving and two gasket changes later decided I needed to try something else. Since my intake is aluminium I didn't dare try and tighten it past the specs very far, so I went to NAPA and got some good thick gasket material and made a gasket. After getting it all cut and some putting on a little permatex, I bolted it back on and have never had a seep since then. I made sure the gasket I cut covered the whole area of the intake and housing. I don't know if it was the thicker gasket material and permatex or if I just got lucky. I won't pull it off to look unless it should ever start again.
Ron
