The problem is most likely in the pump. Be sure that the spring and piston are able to work freely within the bore of the pump. ALso check for flat surface of the end plate of the pump. If the gasket was blown out once, it is probably blown out again. Over gasketing is not the answer, getting the end plate resurfaced is. I suspect that the tighter clearances due to a rebuild may be creating an increase in pressure and thus, exposing the weakness (bad surface of the end plate) in the pump. I think IHC may have new end plates available but the last I knew, they were ridiculously expensive. A good machine shop should be able to make yours flat and such that it will hold that paper thin gasket.
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