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Update. Did the rebuild of the cooling system and the thermo housing can be moved 180 deg so the large outlet faces down, which gives a better hose run to the rad and gets rid of the airlock u bend.
Fitted new starter relay ran the engine to check cooling and shut it down before I gassed myself in the workshop. Few seconds later it started cranking again while my back was turned. Got the battery cable off but it was too late the ni-cad battery hade a hissing sound and a nasty smell, so I think that is dead now. I have thought long and hard and am convinced I have the wiring correct. I am going to try to free off the relay and  put battery on with a crocodile clip (quick release ) and jiggle the wiring round and see if I can find the fault.

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Been working on cooling system now exhaust is done. Bought TDM850 Rad which has a pressure cap thinking i wouldn't need a separate expansion tank. Now the rad is mounted as high as i can get it, the filler is not the highest point on the system so will need a small expansion tank to fill from. Ordered a RS125 one that should do the job. Fitted some hoses but need some more bends to plumb the red in neatly. Its very congested and tricky round the water pump area.

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