Sealant

Did you torque the screws in the oil pan directly after apply the sealant?

Most sealants recomend a short delay to form a 'skin' - it should have some directions for the recommended process.

Personally, I generally apply it, put the cap/plug back onto the tube, get the fasteners ready with the tool(s) required and put it in place without much delay. However, I normally start a few threads on each fastener (depends on number) before running them progressively down, and this may act as the 'skinning' delay?

One HUGE issue I see, even with otherwise VERY good builders, is way too much sealant being applied - IMO, mind. If it's squishing out the outside, it's squishing out on the inside and just something else to break off and cause problems.

Thank you Gord.