Well,shit... lol
First thing I would do is spend a few bucks on a decent quality temperature gauge and make sure the factory one isn't just screwed up.. it happens. Next I would do a compression and leak down test to make sure all the exhaust is making it out of the cylinders and you don't have a stuck exhaust valve. If everything checks out there you know it isn't a valve and you know it isnt bad rings or a bad head gasket. You mentioned that it is "full before you start it" which likely means it isn't full after it runs hot... which means it is getting out somewhere, if you dont see any leaking on the motor at all, no vapor in the exhaust or anything else it is likely something simple.. here is what it could be.. i know it sounds stupid but.. replace the radiator cap, a bad one wont hold pressure and will do exaclty what you are having problems with. also check to make sure the place the radiator cap sits inside the radiator fill neck is flat.. try it with something like a really large washer and make sure it doesnt rock back and forth... it could be a defective radiator or one that got to hot and warped.
In addition to everything else check the tranny fluid and make sure it isn't old or dirty or discolored, it can cause a motor to run hot for a few reasons.
A bad 02 sensor can cause the motor to run lean which can cause the motor to run hot, not normally at idle so i doubt that is it.
If your cat is getting realllllllly hot but the exhaust just behind it is relatively cool that means it is stopped up, which means it needs to be replaced (or gutted) so the hot exhaust can get out.
I know you think the thermostate is in the right way but if it isnt it will sometimes not open fully or properly and will cause the motor to over heat.
Do both of the radiator hoses get hot or just one side before it over heats? if just one side this is an indicator of a possible bad water pump, yes... unfortunatly, again.




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