Driver+Passengers wrote:I believe this is what you might call a coolant hose that is "on it's way out".

Thanks to Peter and Dave for helping me out today!
After taking (cutting) this hose off, it was quite clear that the reenforcing string was absent from the ballooned section - suspect that once liquid penetrates the wall it rots away and the hose then balloons. ?
Anyway, dropped stat (marked 82 degC, Dave reckons Blueprint) and drained the coolant. Also took off the header tank - 5 minorish cracks in the bottom of it and the state of it inside was pretty poor. Used some engine cleaner and sloshed around which dropped a fair bit of sediment and then rinsed thoroughly. Hosed through the system and refitted the same stat fitted the new hose. We did a vac fill but after idling for a few minutes, the rad fans came on. My front stub temperature sensor was still reading 20-30 degC!! We determined that there was still air in the head and reverted to a cold see-saw before doing an idle see-saw and progressing from there. Fitted a temperature sensor to the funnel for Dave - he was reading >50degC while the hose stub was only in the mid 30s. Then I realised I was reading the wrong gauge (engine bay), checked the other which was around 60.
We carried on from there and quickly got the stat open, rad fans on, etc... Every cycle was producing air, and it kept doing so. We totted up how much coolant we'd mixed, and how much was still outside of the van. Started worrying about a leaky head/gasket pushing stuff out. I popped the header tank cap off again and the tank was empty.
Topped it up (2-3 litres), popped a 12V spot light in the space behind the tank which showed the level nicely, left cap off and watched level like a hawk while we revved and bled some more - stat was already open at this point. Shortly thereafter we were satisfied and after 5 or 6 miles, checking every mile, we drove up the longest, steepest hill locally that I knew of and went for chips in the village down the other side.
Seems to be reliably 2-5 degrees higher than it's ever ran before - suspect different coolant (or minor air lock?). Now waiting for it to cool, check level, etc...
Moral of the story - vac fill may not be perfect, but more importantly.... RTFM!!! RTFM!!! RTFM!!! RTFM!!! RTFM!!!
(PS. kept the story of the bleed in this thread because I cannot be 100% certain she is not still "gonna blow".

Given that we're preparing for a 1200 mile round trip.