carbon is on the right lines.
With your current system you are probably never actually filling the system. When it gets warm and would normally force air out of the rad overflow you are actually blowing coolant out because the air is in the stat housing as that's now the highest point.
Get a Metro stat housing with the takeoff and run it to a pressurised expansion tank. Put a bolt through the overflow pipe on the radiator and change the rad cap for a none vented one ('60's diesel Land-Rover oil cap is a candidate that fits).
Put a thermostat back in whilst you are in there - they are there for a reason and just having the fan stop and start is not enough of a substitute.
Iain











