Larry,

I see in the emails that you replaced the overflow bottle CAP, but did you
replace the bottle itself?  They can split in a hidden location and let out
wisps of steam & enough pressure to cause boilover.  I had a terrible time
isolating that as the problem on my vanagon a few years ago.

Wait - I don't mean the overflow bottle just behind the license plate - I
mean the bottle that houses the pressure cap and the water level sensor.  On
my ETKA, it's just called the reservoir.

Randy, Carla & Anna Huyck, Olympia, WA
'75 Rustfalia
'85 Vanagon GL
'74 Super Beetle
'01 Ford F150