Yeah, and that one is actually a rather clean one!! The engine builder put the intake on, so I can't say for certain if he used any sealer....no other gasket though. You mentioned a "better" valley pan tin....where did you get it, part #??
Thanks for the tips on measuring. The block was milled a small amount. I doubt the heads were cut on. Engine shop didn't mention it. The engine is sealed externally really well...to my surprise....no oil leaks on the valve covers, valley pan outside, front or back of engine.

So, you had the same problem....what exactly was the "fix" in your case? Just extremely careful alignment and a better valley tin?