Killerbee - nice article on the LLY overheating issues. I had one that ran hotter than my LB7s, but didn't overheat. Guess I got lucky!
I tried running the cap loose during cold weather pressurization and it puked it out the top of the resevoir instead of the overflow tube. At that time, the focus was on snowplowing and simply keeping the truck running.
I'll drill one cap and see what the results are. Thanks for the idea.
A nearly new '03 DMax engine will be delivered Tuesday. Maybe I can leave it on the shelf for awhile and save money for the labor of the swap. Its a shame to pull a perfectly good, smoke-free, non-oil using LB7 for a $10 gasket.