Well further investigation revealed that the cooling system wasn't de-pressurising correctly, hence the catastrophic failure of the radiator.
I have now re-designed the whole system, using an aluminium pressurised header tank with non-pressurised plastic expansion bottle, and a new aluminium radiator (will get my upgrade after all!).
Thanks for your suggestions Mike, I will ensure the header tank is mounted as far up as possible, though I don't think it will fit on the bulkhead itself.
Now just got to fit it and then test it . . .
Tim
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