Thanks for the comments guys, and the very comprehensive post EB
Before doing this rebuild, I read each and every thread/howto/manual I could find on the procedure. My head bolt holes were clean, I fingered the bolts all the way in and out prior to actual installation, and lightly lubed them with clean motor oil prior to final install. It really seems that this was probably all caused by not retorquing the bolts. I also am sure I used the FSM torque values, with a metal lined HG. Probably needed a bit more #'s initially, followed by a retorque after running it.
I'm unsure at this point what I want to do with the head. Its been shaved once when I just had it rebuilt, but I don't know if it had ever been prior to that. I never overheated to the point where I was in the red, but the temps did rise to 3/4 or a bit more maybe twice. I just don't know if I want to gamble on this head anymore and I'm thinking a new head from EB may be the way to go. I picked up an OE gasket from Toyota this time around and haven't decided if I'm going to reuse the head bolts, buy new ones, or go for ARP studs this time.
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