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Lovely! I am very thankful for your efforts Douglas! I am also excited to give it a go once I get back.

The large outlet tube had been machined down until there were two small holes in it. It also had a deep groove along that tube.

I can't thank you enough Douglas! Simply amazing. I am off to Amsterdam and back on the 21st. I was in the area and stopped by to see one Hillbank had in their parts stock. These are made at the factory. It was in worse condition. I will post pics. Folks, if you have a recent SPF that...

Interesting! Thanks for the inputs. The fans cycle on and off to regulate the heat too,n no? Is this not a major factor? They react faster than a thermostat I suspect. Just curious...

Are any of you using a Restrictor instead of a Thermostat?

How can I not take you up on this most generous offer!? Please DM me your address and I will get it out to you. Thank you in advance!

The hole in the thermostat gasket is smaller in diameter than the thermostat flange. Therefore the gasket rests on top of the thermostat flange. If that flange is above the housing surface, then the gap in space results in reduced gasket adherence and coverage. It was leaking where the...

When I pulled it back apart, the gasket still held the thermostat in the housing because I had thin coated both sides (per your suggestion); the thermostat was not displaced. I pressure tested and could hear and feel the air coming out of a specific location (along the outboard bolt side).

I agree that machining would be the best solution if possible at this point. Note that the mounting flange varies in thickness too. How does one machine this thing down the correct amount? I will be tacking the thermostat down - great suggestion! I mean the previous install was just sealant...

Yes! This thermostat version has a small hole already. I am thinking of enlarging it...

I actually had time to screw the bolts in and measure. They don't bottom out but remain about 8mm off. Here is a simple drawing I came up with so when I get back from traveling I don't have to start over. Right now I think a FelPro gasket with hole widened to clear the protruding thermostat...

Great point! I will screw the bolts all the way in before starting this effort back up when I return.

Bolts measure about an inch in length not including washer thickness. The hole depths are about 1 inch. The thermostat housing is about 0.4" thick. Then there is the gasket, etc. I think I can rule that out as a cause.

Jean Marc, I like this idea! I think I will try it or the stacked gasket variant! Lee, I didn't say that quite right. The housing design is such that the right screw is slightly behind the large hose outlet. I tightened both screws with Allen wrench the best I could. I wondered if that...

Thanks Markus! I am going to do something like a double or thicker gasket as a backup if the thermostat housing Hillbank has doesn't look any better than the one I already have. I agree David mono. Why aren't there more options out there? Or are there?

I am willing to try that Blas! I was hoping the parts would be better quality, but I am interested any solution that will last. I could see buying two FelPro gaskets, trimming one for a larger thermostat hole to clear it outer edge (if that can be done), and stacking them with a thin...

Thanks DaveM! I used right stuff in my earlier attempt and it leaked a little, but still leaked. Now it definitely leaks more. I think I see the thermostat flange at a slight angle in the recess due to uneven machining. I will measure the depth of the bolt holes and bolts. I guess I could...

I was looking at pictures of the Hillbank one I can get, and the quality looks similar to my old one (I.e., not the best). I see a casting void (although smaller). I also see a restriction created by the right angled welding and mating piece. Does anyone make a high quality unit that right...

Unfortunately, the leak is worse now. I suspect that the recess in the thermostat housing that accepts the thermostat is not deep enough. I base this on caliper readings I just took showing the recess is between 0.75 and 0.98mm yet the thermostat flange thickness is .100 to .104mm thick...

Back at it for a little while: I followed Lee's instructions using JB Weld, 320 sandpaper on glass, a new FelPro gasket and the Permatex Sealant thinly applied. I will wait 24 hours before final torquing the housing screws and retightening the hoses. A pressure test will follow soon after that.