Freakin' water outlet won't seal!

OwdKasd,

You're too right, it shouldn't be a problem at all! All thing's considered, the radiator cap relief valve pops open at arround 0,4-0,6 Bar, which isn't moch of an over-pressure compared to.. well anything!

What sort of housings have you done up? Any of those cheapo pot-metal things? Granted, they might work with a perfect manifold seal-surface etc..