Could it be an airlock? - I haven't tried to bleed the system - by releasing the return from the heater to the bottom hose I think might do that?
Any thoughts?
An airlock is a distinct possibility.
I had one on mine. Took the input hose off, in the engine bay, filled hose while holding it up as far as I could, thumb over the end and refit as quickly as possible. Run car, check for heat and leaks.