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Allen:
Regarding the coolant issue:
1. Would you suggest that one use perhaps a 1/4 inch line for the bypass return if duplicating your system? That would keep the pressure down. Perhaps 3/16 would be sufficient.
2. Alternatively, would a 1/8 to 3/16 inch hole in the thermostat (permitting some coolant to flow when closed) accomplish the same goal? My impression is that one wants to even out the temperature in the system by keeping some flow of coolant at all times. A hole in the thermostat would accomplish that. (I used that trick on the GT and it worked well).
Did some head scratching to understand why that happened. My impression is that with a conventional setup the pump is drawing the bypass coolant directly from the block so there is no pressure in the expansion tank with its separate feed from the water pump. But when both the expansion tank and bypass are combined the pressure from the pump through the bypass causes the problem you noted. Makes sense now, but would not have thought of that before your discovery. Now one can see why Ford put two separate inlets on the water pump rather than "T"ing just one.
That top looks absolutely marvelous. Really sets the car apart. And your execution is excellent
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