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You all are the best! I have read and considered all of these posts and Brian has just summarized what I have found in my attempts.
Today's test drive went perfectly well.
Engine ran cool and no overflow.
Thermostats are back in... and mine are high in the hoses just under the top tank on the '35 radiator.
I added a 'catch can' as well a month back to keep from blowing it out onto the roadway as it was doing.
I cut out a new radiator cap gasket using Felpro gasket material and so it seals pretty good.
Skip Haney also provided me a 3 PSI pressure valve that I have placed on the overflow tube between the radiator and the 'catch can'.
All this to say that I may have hit on the right formula.... but i'll keep watching and posting if anything changes.
I do apprecaite all the advice on this forum. Thanks all!!!!