Was the intake purchased new or used? I'd imagine new since it didn't look dirty. If none of the vacuum lines are compromised, I'd be interested to see if the intake has any hairline cracks in it (if it were my vehicle). I know it's not the most fun thing to pull back off especially since it's been done 3 times now but I'd imagine a crack somewhere in one of the runners, where the throttle body meets, or somewhere else in the intake is a possibility at this point.
I'm not the most well-versed in intakes though, so take it with a grain of salt.