Tom,
I have seen those later series thermo-housings crack from the stress on
the mounting ears. They are almost paper thin and I would inspect yours
for cracks. For thermostat gaskets (and almost everywhere else), I use
an industrial .030" thickness, green colored, non-asbestis gasket
material called KLINGER-SIL #C-4401. All the paper/cardboard/cork
materials are usually junk. Luckily, there is a gasket supplier here in
Dayton where one can buy the real good stuff, like what I described
above. The "Ultra-Blue" and "Ultra-Grey" RTV compound is the best that I
have used and I would use them on the gasket. Also check the flatness of
the thermo housing and plane it flat with a belt sander.
Jan
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