It was probably your thermostat all along then... Metal vaned ones don't fail - but sounds like you did what I did with overfilling then which would eventually knack the bearing of course.
I put my cover back on today (now I've established I've no leaks...)
Yeah, took me around 20 mins (with pulley on) - I reckon the trick is to lever the bottom behind the pulley (er gently of course
) - if you can get the 2 lower protrusions behind the pulley while avoiding the toothed water pump drive pulley with the sleeve of the lower bolt hole... oh just **** it with a big hammer! 
that's a first - I've been automatically censored! :devil:
I put my cover back on today (now I've established I've no leaks...)
Yeah, took me around 20 mins (with pulley on) - I reckon the trick is to lever the bottom behind the pulley (er gently of course
that's a first - I've been automatically censored! :devil: