i like this repair option too often we get caught up on rebuilding it better than new bc we have the technology but most of us dont have the time or money i am excited to hear how this works out in the coming months

Sounds like you've got it chillin', so time for grillin' - Rover gods lust for meat roasted over flames to honor them....

Im excited too!

And, yeah, that was basically the point of doing this. With my "stayed at a holiday inn express last night" expertise, I figure this stuff should work better with a small crack sandwiched in a block than a gap in a flimsy piece of gasket. Plan to update this thread at pertinent intervals and time will tell.

Haha lets see what happens on tuesday, then we shall feast!

Oh, just for posterity, the Silla radiator is not as thick front to back as OEM Rover.

Ok, got the drive shaft put back together and installed. It needs and alignment, 60k fluid change, and an ultraguage, but the experiment starts now.

My wife is gonna start using it as a daily driver...we'll see what happens

You are a brave man...

The line between brave and stupid is a blurry one

Also, her commute is about 8 min, so the chances of utter catastrophe are slim.

800 Mile Update

Put about 600 miles on her last week...highway, city, rush hour stop-n-go. Temps were still 194-203.

Still had a little bit of waterfall sound, so Saturday morning I opened the overflow bottle (level stable for the whole week) after vehicle sitting overnight. Pressure pushed the level up till a cup or so of coolant came out. Wife drove it about 150 miles Saturday-Monday.

This morning the coolant was about a cup low, more or less commiserate with what overflowed out. Opened the cap, no pressure. Filled it up and took it another 50 miles to work and back...morning temps 190-195, afternoon (80* with rush hour traffic) 194-199. I think the waterfall is gone, or at least improved.

So, for the most part, hunky dory.

Only issue is, ever since opening the cap on Saturday Im getting flashing SES p0305 (the bad cylinder).

However, it only comes on when starting up after sitting for 4 hours or more and there is no white smoke or coolant loss. If I clear the code it's all good for the drive, and doesnt come on if you just park for a couple hours.

I have new plugs and purportedly new-ish STI wires (from previous owner).

How little coolant has to leak into a cylinder to cause a misfire?

Any other ideas?

it appears you still have slight leak, why don't you pull the plugs after it sits and crank it. see if water sprays out of one of the plugs.