Finally finished my HVR (HV-Maxx Powered CF G2R) - Lots of pics too.

[BP-Revo]

What? Both leak? Very interesting. I have never had a single leak problem. I do have one question about that: Did you ever slid the threads of the shock shaft through the seals while the cap on the bottom of the shock body was tightened? That is usually what damages a seal during assembly.

A little heavier than a 2.5R would put you at about my weight, if not a little more.

Here is what I recommend:

Get P3 rockers (I know alot of people like sticking P2, but they really arent that different other than they resist bottoming out more).
Use Purple Springs front and rear (or blue up front - I need equal springs front and rear because I have a heavy front).
Use 90wt shock oil (trinity sells it).
Set your roll center to normal up front, and use the lower one in rear.
Set your ride hieght to the medium hole, and give a good bit of pre-load in the rear. You should only have 15mm of downtravel in the rear. Set your front so the arms are about 15 degrees from level.

This should be a very good setup. Also, use 1 degree of negative camber front and rear (measured at ride height) and 1 degree of toe in in rear, and 0 to 1 degree of toe in up front. Set your caster to maximum.

Hope this helps.