[rdorman]

Sorry, redundant question.

I find it very interesting that you able to go through break in with out overheating. Also find it interesting that at 220 degrees it is puking into the recovery tank.

I know water boils at 212, 50/50 anti-freeze raises that to about 223 and with a fifteen pound cap that raises it to about 270 or so (even over about 240 with a 7 pound cap). So if the 220 is accurate, why is it puking? That does lend to the head gasket theory(hot spots) but then why did it not happen when you broke the motor in?

Have you tested the cap and its seat as mentioned earlier? If the gauge is correct and the system pressurized then it should not boil over at 220. I would pressure test the system and the cap as well as verify that the cap is seated properly before I went to all the trouble of pulling the heads.

Do you have an infrared thermometer (or something suitable) or have access to one and can measure the heads at various locations to see if they are being evenly cooled? I would think the head gasket problem would show itself this way. Any one checked in this fashion?

Rick