Thank you everyone for your responses. I have been away because of family issues and just logged back today.
The truck is completely stock including the 235. I installed the thermostat correctly and it did work when I placed it in a pot of hot water. (It was fully opened by 180 degrees according to the "kitchen" thermometer!
I never tested the heater hoses when the engine was hot. Not sure if the "kitchen" thermometer would read correctly on it anyway. I was always told that if the hose is too hot to hold... its too hot for the engine. When it was running hot, the heater hoses were too hot to handle.
Yes... the hole was drilled on the flat area of the thermostat and it was installed correctly. (I double checked it myself thinking the same thing.. the only "stupid" question is the one not asked!! :-)
My plans are to flush out the entire system and have the radiator cleaned and pressure tested. For now it is resting in the garage and comes out on the nicer dryer days (which seem to be leaving us now here in the Northeast)
Thanks again everyone!!
