Any luck yet? .004 isn't much movement at all, any good lip seal would take that in stride as they're designed to deal with slight misalignment issues, what brand seal have you been using? I generally use Felpro exclusively, I was just looking at the pic of your balancer hub, looks kind of odd, that your sleeved one? You said you have purchased a new one that still leaks? You are positive it's leaking between the seal lip and balancer hub? I'd be pulling the seal out of the timing cover and very carefully measuring between the crank snout and the wall the OD of the hole in the timing cover seal outer edge comes in contact with in several different areas around the seal area of the timing cover to make sure the crank snout is actually in the center of the hole, you said the block was out of the machine shop stock as your original was damaged beyond repair? That means you really don't know exactly what's been done to this block over the years? As mentioned earlier If it's been line bored more than one time or even excessively one time that will put the crank center line deeper into the block, that is closer to the camshaft center line and that could cause your constant excessive leak as it would be heavily against the upper lip of the seal and very little pressure against the lower lip, I'm not a pro engine man by any means but I've built my share of small blocks over the years and have seen that issue a time or two so that's where I'd look next as you've exhausted about every other avenue possible that I can see, Good Luck!!