Ok. Refilled the coolant today, and might I say he's running like a dream now!
Some frustrations. Sheared one of the shielding bolts getting the drains. Lost the BLOODY radiator vent bolt when running in. Missus got shirty when I called her out, apparently holding your finger over a hole of boiling water isn't a good enough reason to shout. What that long bolt? Surely there's a better way. I had trouble putting it in when boiling fluid wasn't ejaculating all over the place!
Took a while to flush all the brown crap out of the system ( anxiety now) and then started the filling with this from Baxter
http://www.brick-yard.co.uk/forum/bleed ... 29710.html" onclick="window.open(this.href);return false;
Now instead of getting to twelve o'clock and spewing water out the expansion tank, it happily went to one o'clock without incident. Even got the high speed fan to come in. And no drama!,,
Kevin, I found a small blockage in the elbow of the last connection on the rail. Some wire sorted it out. All the other connections were ok. Replaced the dalek, thermostat, and upper housing, and some *#€¥$?¥ rusty jubilees. Added 8 litres of concentrate. Lost a little during radiatorgate. Only added about four litres of water, and I did keep checking. Figure some water was left in from flushing.
So I'll give it another go ASAP and recheck levels etc, but I think it's running better than ever.
Now for a long hot bath. My body is in pain from all that contortion!