Re: Pressure test plate
I'd make it out of thicker material . . . unless material cost is your big issue. In the end, the coast of the material is small (in my mind) as compared to the time/work put into the end result. I'd probably go with 3/4" myself - but Hey, that is me.
Also, you should take a hole saw and cutout the area for the bore - so you can "see what is going on". If you have time, cut out two 1.5" holes in the valve area. Or, better yet find somebody with a nice big laser or waterjet cutter and cut the center areas out to match a stock head gasket profile.
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