The woes continue. Decided to replace the thermostat today, got it out, cleaned it up and replaced it with a 82c thermostat. Applied the gasket and tightened it up till it was snug. Started the car and leaks from the bottom of the housing...So I loosened the screws and cranked it back up again thinking it hadn't seated evenly. This time I cranked it further and the housing cracked.
Not sure if the leaking was caused by a crack from the first time I cranked it. Anyway upon pulling the housing and gasket out, I found the gasket had some damage on it as shown in the pictures below. So I've ordered a new housing and gasket which should be here in a week.
As for getting a good seal on the thermostat housing, do you guys use RTV? Should I put some RTV on the gasket? I found the mating surfaces to not be perfectly cleaned, so I've given it a once over and it "seems" to be pretty good. Any advice on getting it to seal back up nicely?