Didn't see this when I posted...good advice.

 

Some real good tips here, Fellas. I have plenty of 1/4-20 fasteners in all kind of lengths. I like tbugden's idea about making replacement studs if necessary. I have some 1/4-20 x 6" screws that would work. Also like Flounder's idea for guide bolts. I'll be doing that! Yes, I will likely reuse my fasteners unless they are really boogered up. Don't think that's the case but I have backups if I need them. Right now I cannot find distilled water anywhere. Store shelves are picked clean. I'm changing coolant and all the hoses at the same time I'm doing the gasket job. I need new hoses anyway and it will help having them out of the way when I do the gasket job. Just gotta find some distilled water somewhere.

Since I started this thread I researched the idea of using RTV with a gasket (do both together). Lots of people do it. Some implore you NOT to do that. What is consistent are those who do it are weekend warriors (like me) and the ones who implore you not to do it are professional mechanics. Tells me everything I need to know. RTV is out!

 

Job done. Went well. Few bolts a little tough to get to but doable. Worst was the corner stud on right side next to back of alt. 1/4" drive w/deep well socket and swivel was all I could get to work without taking off the alt. I did re-use all the hardware. It was in good shape, just cleaned them up. And I used Flounder's tip by making guide screws to hold the gasket in place during cover mounting. Just used 4 of them, the rest lined up fine. Worked perfectly. Excellent tip, Flounder!

 

Happy to help