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Take it from someone who spent hours upon hours trying to save a rare gas tank that was not-reproduced: Once you have a problem in one spot, the rest of the tank is probably too weak to save also. Do yourself a huge favor and buy a new one!

Turn the tank on end, soak with penetrating oil, let sit, and give a light prys all around with a screw driver. The gasket is probably petrified.

I ran unleaded premium in my Charger from 1987 - 2010 (+/-). I had ported the 906 heads and wanted to save them, so I pulled them to put stock heads on before selling the car. They were ruined.... the exhaust valves were so sunken into the seats I tossed them in the scrap bin. That was maybe...

No. You can block it off.

IMHO, it's best to work with what you have for now. You don't even know if this engine is any good yet... so I wouldn't start a shopping list just yet. That carb looks pretty fair to me....pop it open carefully to save the gaskets, clean it out, reassemble, and use it as your starting point to...

Once you break it lose and get it to turn over, try and get it started first. No need to clean valves/lifters/pushrods etc. They should be fine for a start up even with gunk plastered to them. After it starts and runs, then you can assess what is next.... run as is, clean stuff, partial rebuild...

I did this on my 70's Mopars that had the OSAC spark retarder. Pass the vacuum line right through it....

You've have had the carb apart 10 times and are describing some weird stuff where it seems to be alternately lean and rich. If I was you, I'd save my sanity and switch to another carb. Someday when you are bored and all of your classic cars are running perfect (ha!) you can go back to this carb...

I have never used anything but RTV on the valley pan and NO gaskets whether it is a stock intake or aftermarket. I bead the RTV a little so it seals anything the pan does not. First the bottom of the pan and then lay it down, then on the intake and lay it down on the pan. And yes a little extra...