Rockledge--How much sealant did you put on your gaskets and where did you put it? I put about a 1/8" bead just across the 4 cylinder head-to-intake gaps where indicated in this picture. Did you use any other tricks or techniques when installing yours?
I did what you did...added some RTV support in the "step" area, per the instructions. (See page 3
HERE). As for how much sealant, I can't recall specifically the amount, but I'd guess a 1/8 to 3/16 inch bead.
FWIW, it sounds to me like you've done (and previously did) everything by the book. I hope things work out a little better for you this time.