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I am sorry to hear of your continuing problems.
At the site of the housing placement on the head is completely free of corrosion and buildup? Can you see any obvious loss of the surface that would seal with the gasket?
Do you feel that the pressure in the system is not excessive?
If I was dealing with your problem I would remove the thermostat and make the area around the opening on the head pristine clean and dry- pure aluminum staring me in the face. I would then add a layer of RTV silicone in the area that the gasket sets against the head. Making sure the housing and (new)gasket are clean and dry I would install them on the light bed of RTV, allowing it to set up overnight before adding hose and coolant.
Don't overtighten the nuts on the housing- they are not very large and snapping one off will only ruin your day.
Good luck
Randy
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