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While you're doing the sender and t-stat, replace the bypass hose.

You install the T in the hose from the engine into the heater core inlet.

Are you referring to the "Prestone" reverse-flush kit ? With the yellow plastic T-fitting ? We used to do installs of these every now and then during a coolant system service.

If I may ask, how did the pulley get damaged during removal ?

You're putting a 26" rad into a 22" opening ?

Whatever you do, don't get those cheaply-chinese made chrome repro ones, they are guaranteed-leak garbage.

A few years ago, on one of my cars, I installed a Champion. Big mistake, piece of garbage. Factory radiator/shroud/fan/clutch is what I recommend. Works perfectly on 4 of my other cars.

Oh, ok. Then just install a factory setup. Glen-ray radiator, fan, shroud. Worked then, will work now. If not, you got another issue.

Spot on. Then go to a champion mistake, and all downhill afterwards. What was wrong with the factory set-up ? Worked then... should work now.

I currently have a Wizard in my 70 B-body, fits perfectly and the stock shroud fits perfectly. Just used the shorter Hayden clutch. Cooling performance fine. No drilling or modification was necessary. ( Had a champion beforehand, piece of junk )

Do you have a good radiator shop nearby ? They can boil-out or recore your existing radiator. I'd bet that would cure the symptom.

YOUR words: "I have never had a cooling problem until then. Even on hot days, the 360ci in my '66 Belvedere rarely went above 190 degrees." You had a system that functioned perfectly. And you changed it to something different. Yes, there was a malfunction. Correct the malfunction, but you...

Let's "boil" ( pun intended) this down to basics: You replaced a system that worked, with a system that doesn't work.

Hey, I've been playing with cars 50+ years, and I learn something every day. It's remembering it, that's the problem :lol:

I don't mind, if it helps !

Exactly.

Why do you have to take the bolts ALL the way out ? just back them off to remove the fan. Put the shroud over the front of the engine, re-install the fan. Bolt shroud on radiator.

Wizard Cooling. Fit perfectly in stock mounting. Stock shroud fit perfectly. Since it was slightly thicker, I used a short Hayden clutch. Zero fabrication. Cools as it should.

Do you have a FSM ?