Chris, thanks for the reply.  

I did check one of the main bearings with the plastic strip when I put it together and it was within limits.   Just checked one.

I did not put any sealant on the new front main gasket; just soaked it in oil.

I installed a new oil gauge and also checked the pressure with a second one.  The oil pressure has always stayed out of the red, but not clear to the right the way it did before overhaul.

I don't think I know about the relief setting on the oil pump.  Can you tell me about that or refer me to the pages in the service manual?   I did replace the oil pump with a used one because the machine shop broke off the mounting flange by putting too much pressure on the bolt.  The pump appeared to be about the same as my original one.  But, this could be the issue with the oil pressure.  Guess I could get a new one ($300+?).    

I did check the oil relief spring and small &quot;piston&quot; in the block.  They seemed ok, not stuck, but I replaced the piston.

Most of the oil pressure questions we are thinking of would not account for the oil leak in front.   But maybe there are just 2 separate issues going on.

Please let me know if you have any more thoughts.   Otherwise thanks very much for the time you've spent on this.

Tom