In all my years, I don't think I have EVER had a t stat housing that did not have a leak, no matter HOW much I cleaned and made sure things were flat, etc. . . . . went with this :

http://www.terrysautolab.com/

Have not had a single leak with this !! . . .Yay O ring seals !! . . . I am not too worried about "non stock" look, so for me this was THE SOLUTION !! . . .well worth the $$$

Good luck . . .