Just throwing a few things out here...
Are you using the same torque converter? Could it be warped? They aren't expensive, next time you gotta replace the flex plate, replace the converter just to rule it out if anything else.
Now, the flex plate attaches to the end of the crank. Have you noticed any balancing problems (ie: vibrations in engine at higher rpms)? The crank could be warped/bent.
Are you overtightening the flex plate bolts? They don't have to be too tight to function correctly.
One other factor that is relative: the starter. Any grinding noises from the starter/flex plate when trying to start the engine??
SgtDel
aka "Andy"
www.delbridge.net
1979 Big 10 383 stroker
1991 Blu 'Burb 3/4 ton 4x4