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only just found time to read all this (excellent) thread, well done, but one question? No one seems to have commented that the block appears to be wire o ringed. I do this on Volvo 4 cylinder engines which I like playing with. Did you do this, or was the block acquired with wire rings already installed? Obviously it limits you to a compositre, ratehr than multi layer shim gasket, but in my experience a composite gasket will withstand a huge amount of abuse if the block or head is O ringed just oustide the fire land region.
Great thread, very best of luck with it. Only comment would be that I would make a crane to support the turbo and wastegate from Rose jointed rods to keep the weight off the manifold. I believe you will experience cracking, long term, if you don't.
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