Thanks guys, I must admit I had forgotten about bleeding the thermostat housing, do you think that will airlock the syste sufficiently to be a massive problem? (thats the problem, I am playing with VW's/pugs/bikes so my memory starts to go)
I will get a tester to check for CO/gas in the water. ebay? Any trade names to search for?
The head is ported, but just a home clean up.
I suspect a crack somewhere, opening when its hot, but I get bubbles even cold