pprince - news to me too til I read about it in the manual (1969, Vol II, 08-05-10).
mac and Gypsy - no pins or sleeves or whatever you want to call them on the cover or in the block. This is the 3rd engine I've used the cover on. It was on the 302 that was in the car when I bought it in 2004. I was a newbie to this hobby back then... wondering if those sleeves might have been junked with the engine after it blew up one fateful night. There weren't any on the 351W (75) I replaced it with, and there weren't any on this 351W (72) either.
Huskinhano - after 3 pages of questions and advice, I feel like an idiot. When I pulled the timing cover and saw that the bolt came loose, I slid the timing set back in place (so I thought) and the dowel was flush with the gear face, but never tightened it up. If you look at my last post on the thread... well... yeah... (don't tell anyone)… when I tightened up the gear the dowel popped out 1/8". Go figger
Woodchuck - I just happen to have various pieces of PVC pipe hanging around the garage, along with some drum sander bits, and a drill press. That idea just might work.
Thanks guyz!