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Did you check the head was not warpped before fitting a new gasket
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It didn't look warped when I changed the gasket but is there some way to check other than with your eye?
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Going back a step did you drill/tap the hole in the manifold while it was on the head?
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no it was on the bench...
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When engine was stood it would not have had antifreeze in as you were topping it up to get home, so is there any chance of frost damage from residual water in the block/head.
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again i dont think so as it was drained of fluids and the engine taken out and sat inside on the garage floor over the winter.