Updates:
1. No longer a urgent thread, could a mod move this?
2. Still leaking... but I think it's the evaporator. As soon as I turned on the A/C I smelled refrigerant, but I assumed that was residual from the explosion. Obviously that's not the case (duh), so the saga continues?
Update:
Swapped the evaporator and liquid line today. Made a nasty discovery:
That's the O ring from the prior posts. Still had the wrong one...
The new evaporator came with new O-rings, so I was for sure able to get the right O-ring. This time the fit was a lot better.
I replaced the variable orifice tube with another variable orifice tube, as the input screen had some junk. A little bit of metal (not unlike what I saw from the bad fitting connection awhile back) and some fiberous crap. Nothing massive but $20 is cheap insurance.
I also bought a new vacuum pump. It's a dual stage 3CFM one from Harbor Freight, pulls a much better vacuum than the $20 venturri one I was using. I could actually see water vapor being pulled out. Got it down to 30 inHG and let it sit for 30 mins... My needle didn't move a hair. Charged it up... so far, so good. Not calling it "fixed" as it hasn't been long enough to say.
On the plus side I haven't been hearing much compressor noise (the bad kind, that is)... so that seems to be a non-issue.