Couple of set backs:
Last weekend boy-child was sick; trumps working on the car
This weekend we pressure tested the cooling system and the upper reservoir tank was puking coolant into the overflow tank @ 4 psi. Not good! We thought it might be the seal of the radiator cap, but no that would be way too simple. I grabbed the one off the STI and we had the same issue.
I took a close look at the seat of the coolant tank to see if there was any debris or something that would prevent a good seal. Sure enough, there’s a hairline crack I didn’t notice earlier –that’ll do it.
Replaced the coolant tank with a ‘newer’ plastic one – looks like it belongs there – and problem solved. Holds pressure up to 16 psi.
Really trying to get the engine started soon!