Well, Dan is on his way home, driving his 96 SSEi.
The Check Engine light is on, o2 is more than suspected, and the stock boost guage is now indicating 2 psi more boost than it did before the SC porting.
We found the old TB gasket had not been fully removed, the lower section was gone from the original, the new gasket had been installed, but it had a gap at the bottom, thus causing a vacuum and coolant leak.
After some brainstorming on possible locations for coolant leaks in areas we had worked in that was deamed the only possible place as we had already pulled the SC off to verify the O-rings weren't damaged/not seated right and every thing else looked good.
We removed all the plugs, cleaned them, cycled the engine to get the coolant out (took one revolution after the TB was sealed), put the plugs back in, and it started right up and ran smooth, despite a LOT OF SMOKE. Ran the engine for 2-3 minutes, drained and replaced the oil and filter, and then took it for a drive. It definitely felt smooth and pretty much about how my 95 did after I ported the SC on that and replaced the damaged SC gasket on that. Very smooth and Dan said it was definitely smoother and the boost was a solid 1.5-2 lbs more as it used to peak @ 9 lbs (stock boost guage) at the top of second gear, and now we're seeing 9.5-10 average, peaking at 10.5-11 lbs at the top of second.
Also, I suspect that Dan'* engine, or just his supercharger were replaced previously as his 1996(?) M90 is not painted like the M90 on my uncle/aunts 1996 Park Avenue Ultra.
Needless to say we are both VERY relieved. Like he said "it was probably something stupid" and it was. We won't say who'* to blame though.
Also, 120 grit flapper wheels with a dremel spinning @ 8-9000 rpm create a very smooth SC inlet and finishing up with a 1000 grit wet by hand really is candy.
First time using a flapper wheel personally ---won't be the last time for sure. In fact I have a 98+ SC sitting here waiting to get ported this week.