Of the number of times that you had the engine put together, do you recall the shop grinding the crank for the seal at all? This should be a separate charge, or I suppose bundled in with whatever work the crank may have needed.
I had the 1 piece BOP seal done on my engine last year and I have a specific line item charge for grinding the crank specifically for that seal. On some cranks, those serrations are quite deep and if it was never prepped for the BOP seals, that could be why you continually have problems. If that's the case you'd certainly be better off trying to find an NOS asbestos gasket. Or, you can always take the crank out and have it ground, but now you have yet another complete disassembled engine.
From the video I don't know that I saw smoke coming from the pan gasket as much as from behind the crankshaft flange. Certainly hard to tell though.
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-Jason
1969 Pontiac Firebird
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