Im still puzzling over this one
the bit that doesent make sense is it can be left ticking over for hours or cruising as long as you like and it doesent over heat, as soon as you have been booting it for five mins it gets hot then if you cruise agin it cools down, so to me headgasket doesent fit the bill, its more of a flow problem,either not enough flow or the heat exchange fromthe rad is not enough when boosting, the only thing that you havent done is improve the airflow through the rad by removing the aircon rad and there is no guarantee thats going to work!!!
think as said the viscous isnt going to help when doing high speed but it will help cool the whole thing down at lower speeds,
what happend when you last swapped the drilled stat ? cos the only thing that seems to fit is the stat is causing a restriction in the flow? assuming you havent got a collapsed or seperated hose somewhere in the system,
having the heater on makes a difference againnpoints to a flow problem and the heater helps to improve the flow? does that make sense? the later ones have a hbv dont they? whereas the early ones dont, wwondr if its possible to get that out of the system and try it then?