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Jed, I've had very good luck using Threebond sealant in place of a gasket. Long term usage on a few saws and so far no leaks. I have the sealant type number at the shop if you need it, they make a few varieties.

I know the feeling, too. :( Still, a part of learning.

Maybe you opened up the ports too much. One thing you really have to be careful of, is opening up a port so much that the piston skirt doesn't completely cover it when the port should be closed.

Jed, are you sure that you didn't leave any tools inside like surgeons sometimes do?