Please help! Old element, no leak. New element, LEAK!

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Erosisking

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Like most of my problems, this one defies reason, and I can't find anything about this happening online.
I have an older 20 gallon single element 2000 amp 120v GE. The element had gone bad after years of service, but wasn't leaking. I put a new $10 element from home Depot, with and without tape, and it is leaking pretty significantly both ways. Tried all different degrees of tightness from hand tight to as far as it would go. Put the old bad one back in and no leak! WTH?? Gasket on the new element looks alot better than the old one, except for the water coming through it.
 
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