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I guess I'm going to give up on this, put a new block heater in this weekend, put the block heater on a timer and use the intake heat if the timer hasn't gotten it warm enough by the time I need to use it.
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Make sure the heating element is orientated right so that the element doesn't touch anything iside the block. Essential for long life. I was thinking about the timing and I wasn't sure how changing the timing would raise the heat in the engine. A diesel needs heat from compresion, fuel and air to start. Raising the compression would help. Raising the cetane should help make the fuel burn easier(lower tempature). Once it is out of warranty I might raise the pressure on the injector nozzels just to see if would help. Do you have any good diesel specialist around? I very intrigued by your problem. It's been 20 years since I had engine dynamics. I think I'm going to go through my books if I can find them.
Keep us abreast of your situation. I'm curious.