Thanks for the ideas people..

blackwidow:
Is there any special way to bleed a dsm? I just run it with the cap off till the tstat opens and coolant starts rushing out (heat on full blast) let it go for 5 minutes and cap it up..never had a problem doing that.

scottY:
I ran it with only one fan for over a year (during the summer even..) and the gauge never budged. I guess I will get the logger on it and find out exactly what the temps are when the fan comes on and it starts overheating..

Also I've had a front mount for 2 years and never had this problem. Both cores were tube/fin. I suppose I'll try cleaning out the radiator, maybe pull the condenser out, and I want to make some ducting. Used to have some but I smashed it.

rairai:
guess I never tested it, if it comes down to it I will pull it and boil it to see what happens. thanks.

keep em comin guys, this should keep me busy today..