Hey guys OP here .... thanks for the input. It’s 4th July 2018 and so far so good with the merc. I was hoping to get another year out of it and things seem to be running well. I use it pretty regularly at least 1-2 times a month to keep it going. The overheat was just such a bust I would recommend a raw water bypass to someone as last resort.
My theory is that I had a small leak behind heat exchanger between block and head that was causing loss of pressure and it would boil over. Couldn’t see it with heat exchanger mounted. And fluid coolant boil over masked the leak.
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