Okay, so I have it out, on the engine stand and the pan removed. Pulled the oil pan, oil pump and rear main cap. The sealant I applied at the rear of the cap was definitely sealing that area, and was adhering very well. The bottom half of the seal stayed on the crank as one end was clocked into the bore of the block about half an inch, but came out easily. Used a pocket screw driver to push out the upper half and took them to the bench to examine them. They looked okay, but there was no gray sealant on the ends of the upper seal, but there was on the lower half, which is where I applied it when I assembled it. So, as I surmised, the seal's O.D. was too small, and when assembled, the ends weren't in contact, leaving a gap for oil to leak out of. Makes perfect sense now.
Just to prove it to myself and you guys, The pictures show the seal halves installed in the cap and block with one end flush with the mating surface, and the other ends up about 1/16" recessed in the cap or block. There's the problem, clear as can be.
I was able to get the left header out without removing the steering box, it's close, but by removing the plugs on that side it comes out, barely.
Once I get the parts and get the seal installed, I'm going to roll it over and check the head bolt torques. If they're up to spec, I'm going to pull the right head and change the head gasket. I'm interested in what surprise I find there. I know I used the recommended Fel-Pro head gaskets called out in the head installation instructions. The heads were brand new and he block was decked, so it should have good mating surfaces. Curious.....
Stay tuned guys!