Loren

Just keep it full... it doesn't cost anymore than running around nearly empty.

yes

I haven't measured them and I don't have a micrometer.

Some things I was told about this week: Drill 2 x 3mm holes in the thermostat, one on each side of the existing hole with the bobbly bit. It will flow earlier and better. Use a good oil cooler and make sure the fittings/lines are not restrictive as that can make things worse. Make sure your coolant isn't too concentrated as it will be too thick and so heat up more when being pumped. Also, coolant doesn't provide cooling... that's what the water does. And finally, a thick oil will also heat up more than a thin oil when being pumped and also travel through the motor slower removing less heat... so don't go too thick.

Sorry for the delay. The closest I have is a 499, a 501 and a 502.

I don't know why it's hard to find jap spec manuals... maybe they are all in Japanese and google only looks for english manuals by default? I will look through my buckets and see if I have any to suit.

I don't know what a BP5 Legacy GT should be... I know that GC8 STi had 0.008 and .010 and that is what mine is set to. The USDM 04 STi has the 0.0138 clearance... I have never found any JDM manuals... only USDM. In general though, .008 and .010 is very common across lots of motors. 0.010±0.002 is 0.008 to 0.012... so 0.013 is too big. You could look for a specific manual for you car of course and maybe the larger clearance is fine.

As a rough guide the USDM 04 sti manual says intake is 0.0079 +0.0016 / −0.0024... so your intake clearances are well within that. The exhaust clearance is much bigger than 0.010 on this engine though... 0.0138±0.002, the +/- 0.002 is probably pretty good, so 0.13 and 0.14 is probably on the big side. I have quite a few spare buckets, let me know what you need.

I had the same problem, ruined 2 or 3 batteries, then got a 20w solar panel. Works perfectly.