Im at a loss, ridiculous blow-by please help

[RunawayValet]

Okay, 1G stock motor/new rebuild dr650 car on e85 running 28psi. Was tuning the car after about 1500 miles (dont ask) and started to over heat in 3rd and 4th after high boost pulls. When I checked the coolant I noticed some oil in the coolant, but no coolant in oil. I flushed and decided to keep an eye on it. Shortly after doing some more pulls I started getting some crazy blow-by, blew the hose between valve covers out, blew the camshaft seal caps out. So I bought a catch can, and routed the valve covers to the catch can. No dice, it just pressurized the catch can and blew oil out the top of that. Finally did a compression test and the results were, front bank all ~170, rear 30, 60,and 170ish. So I think head gasket, probly from overheating. I replaced the rear head gasket with MLS, I made sure to inspect the cylinder walls to look for scoring from a possible bad ring, looked good. I replace the head and put it all back together. Now the same blow by, there is actually exhaust coming out of the valve cover vents now. And compression numbers are exactly the same. I know rings are a possibility but the walls looked great. Is there anything I am missing?

Thanks for any help you can offer.

[NOMIEZVR4]

Hmm...the fact that you have exhaust pulsating through your catch can indicates that there still may be a breach in the combustion chamber..now thru what means is what you have to figure out. Did you have the block/heads checked for flatness? You sure you didn't install the HG upside down or backwards? I would grab a coolant system pressure tester and pressurize the system to look for any visible leaks...start from there and lets see where that leads us.

Also while you are at it, pressure test the car and see how much blow by you still have. Recently was working on a 2.4 evo that was just built, it has CRAZY blowby--when pressure testing, so much pressure came out of the oil cap that unless one person wasn't fully pressing down all their bodyweight on the oilcap, we weren't able to pressurize it because of such intense blow by--and thats with a catchcan he had installed too with some really big AN lines.

[anyonebutme]

leakdown test

[TwIzTeD_3kGt]

Describe your "new rebuild". Sounds like the problem will lie somewhere within that description.

[familyMAN]

If you blew a headgasket, you now have a warped head or block or both. Sounds like it is time to pull the engine and get block and heads resurfaced. Also look for busted piston/rings.

[RunawayValet]

I had the head decked for this new gasket, which I didn't do the first time. He took off 4/1000. However I did not have the block checked.. New rebuild meaning all stock parts with new bearings, rings (which I checked with feeler gauges for appropriate gaps) new valve stem seals and re-seated valves. It didnt need rebuilt I just did it because I had it apart.

There is A LOT of oil in the boost pipes, before and after the IC, on both sides, in the bubble, in the throttle body.
When the car runs if I take the oil cap off it looks like the exhaust pipe.

[RunawayValet]

FamilyMAN after doing the headgasket and yielding the same compression results, that most likely was not the issue. Everything leans towards broken rings, but in 2 cylinders?? With no signs of wall damage? I thought maybe cracked block..

[familyMAN]

These blocks rarely crack (if ever). At the risk of sounding like banned member steve, "busted ringlands". As suggested already, do a leakdown test to see if it's valve or ring related. Also pressurize your coolant system to see if you breached the head gasket again.

[RunawayValet]

My leakdown tester is a POS, however when the head was off I made sure to check all the valve seats and they were fine. I will pressurize the coolant system and post back, thanks guys.

[anyonebutme]

you don't even need a leakdown tester, just hook the compression tester adaptor to air compressor and put pressure in the cylinder and see where it comes out