I managed to find a comp at work with internet. Lucky me.
Anyway, I'm terrible at using the quote function, so I'll try to answer each post chronologically:
No carb heater plate in use. Head torqued in order shown in handbook, from inside to out, in 10 ft lb increments from 35 to 75. Oil level seems to be fine, but the pistons and head did seem to have an awful lot of carbon on them for only 1k miles...
I'm reluctant to use block sealer immediately to cure it until I have exhausted all options. I wouldn't think I would need to do that on a new motor, but its looking like I may have to no matter what. Damn shame that is...
All pistons have and combustion chambers had equal amounts of carbon build up and no one cylinder looked like the culprit, i.e., not clean. I'll try the radiator cap trick when I get home tonight. The smell from the exhaust is kind of sweet but it does burn the nose. It's definitely not steam or the result of temp, it's full-on smoke. Filled the garage after 5 minutes of idling...
I have an auto tranny, but I disconnected all the vacuum lines and plugged the ports (the PCV manifold port as well) and ran it to isolate the carb from any potential oil intake. No dice, same amount of smoke.
I'm at my wits end here, it's driving me crazy. I built this motor up over a 2 year period and finally got the car back on the road and now this. I fill the intersection with smoke every time I stop. People roll up their windows when they get stuck next to me. Last resort will be the alumiseal, but I would hope I could sort it out before I have to do that. I hate to have to think I'm running a motor that is depending on a quick fix from Autozone to survive, and that any moment the potential crack could widen. Thanks for all the help guys, and keep it comin!