Has anyone else needed to surface brand new heads? I'm curious how often this is a problem.

As others have stated, usually that much water on a fresh build the intake is the culprit. Hope it is figured out soon!

If it was an intake would hear the air through the valve covers?

also remeber the #5 had water in cylinder originally.

Yes, it could. If a water port (they are at each corner of the intake and head) leaks, this goes directly into your lifter valley. The lifter valley is directly connected (air space wise) to the valve cover area.

Agree with SB

Baja rooster
 

Yes new heads resurfaced. Check anything you buy. I bought my heads and they told me, ready for assembly and bolt on. YEAH RIGHT!!!!!. Ifyou want bolt on heads ready to go BBC. Probably 2000 or so bucks. **** my exhaust valves are 50 a piece. Let's see I paid about a 500 each for bare heads. Had to have guides pushed out seats and deck recut. The rocker stud bosses weren't parallel to valve stem so a few if the rockers weren't sitting square on valve tips. Had those touched up. Now nice heads. 1200 bucks worth of machine work for 2 heads.thats 2200 without parts. Still bare. Now add valves Springs retainers spring seats locks shims. So spend your money on good heads. So all you have to do is bowl blend and maybe assembly. Back to water problem :)

Anyone think this could be a mismatched head gasket issue? Gen 4 block with aftermarket promaxx heads? My builder texted me back and said he would call me this afternoon. Just trying to figure out where this could be wrong?

I initially leaned toward the intake gasket since it leaked that much water but i find it hard to believe he would goof on an intake gasket twice

I'm putting my bet on that Valley pan. Twice in a row. Easy to miss

Ill buy you lunch next time im in new york. (Customer in arcade) if its that easy.

If I was living out that way I would have come out to help out. This thread lit me up. Again sorry your having so much grief and trouble. I'll be running my engine bolted to floor before it goes in. Not doing that again. Hell I still have to pull other engine at end of season