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Paul,
I forgot to address the second part of your question.
Nothing you are inquiring about as a possible cause of your water problem would have anything to do with the leak, with the possible exception of the acid flush.
Since the water leak seems to have developed immediately after an acid flush, it's entirely possible that the acid flush did cause a very thin area of a water jacket to break through. However, if a water jacket is really so thin that the mild acid solution prescribed in our procedure causes it to break through, it's best that you discovered that condition sooner rather than later. In fact, if your situation really does turn out to be as it appears, it would be the very first time that a water jacket failure was reported in the aftermath of an acid flush in the 15 years (or so) that we have been recommending the procedure.
Don
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