Need some help !!!!!!!!!!!!!!!!!!!!!!!!!

Well, if your measurements are all accurate, why would the solder compress down less than the gasket thickness at all points? That seems to be a guaranteed leak everywhere....oh, that is what you are having! Something seems to be hanging up the intake and preventing it from settling down against the gaskets; perhaps the bolts? Almost as if the intake was machined too much.

Sounds like thicker gaskets have to be part of the solution so that the bolt pressure is going against the gaskets and not whatever seems to be hanging the intake up. It seems unlikely for sealer to close up .002" to .004". Wish I could help you with a thicker gasket model number....