| is opening the thermostat. Remove your thermostat and place it in a pot of boiling water to verify it opens on its own with respect to temperature. Better yet, use your portable guage at the same time to tell what temp it opens at. My guess with the temp sensor not reading similar to the gauge you have in the outlet is there is a bubble of air surrounding it due to the system being open. You may need to raise the outlet hose a bit to gaurantee the outlet pipe is full of water... also loosen the sensor to bleed any air that can easily get trapped there. Don't assume because your heads tested fine when they were rebuilt that all is well now. An engine that overheats when all else appears normal typically means there is air getting into the cooling system. This is from a poor head gasket seal which allows combustion pressure to squeeze into the cooling system, at worst it's a cracked head. I would do a standard CO2 test to rule out combustion pressure leaking into the cooling system. I remember your first posts about your head gasket and head bolt dilemas; did you ever get the engine block verified for deck flatness? Did you machine the block and/or heads? Doing this is the cornerstone to a rock-solid head gasket seal and subsequently a healthy cooling system.
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