I would remove the QED remote stat ,refit the standard thermostat into the standard rover housing, check the whole syetem for leaks, bleed system and give it another run before pulling it apart. The coolant expansion is probably due to the system not pressurizing fully, if it were a HG fire ring then the coolant would expand and the system would be overpressurized after a few secs/minutes running. If the HG coolant seals had failed you should have either and external leak of coolant showing along the head /block joint or coolant in your oil or oil in your expansion bottle.
Edited by - Rob Walker on 23 May 2007 09:52:53