Sorry to hear about your canning dilema's. I too use the hot pack canning method to can my sauce. I have used it for several years and have never had a problem. Knock on wood!! I was given this 'secret' reciept several years ago by one of my parents neighbors before he passed. The hot pack method is what he always used and this is indicated in the reciept.
The only thing that I could suggest has already been stated. Make sure that your jars, lids and sauce is ' HOT' before canning. Wiping the rims is very important too. When I use the hot pack method, I always turn my jars upside down for the night. I've never had a problem with jars not sealing.
Good luck to you in future canning projects. I would also suggest that you make a smaller batch when you alter your reciepts to see if there will be any problems. Oh, I also make my jelly the same way and never had a problem with that either. Knock on wood again! Don't want to jinx myself