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Thanks again Dazza, I think it'll be a new head myself but will firstly do a test for exhaust gases in the expansion tank and I'll try doing a vacuum coolant fill rather from the top. Im still hopeful that the over-pressurising is from a coolant air lock somewhere. Bottom hose is still cold so I dunno. It's a genuine new thermostat though I dont know if it opens at 82 or 88.
cheers
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Its very common on these engine that no hydrocarbons show up on a chemical test.
Its not a complicated cooling system, i have never vac filled them.
you could change out the water pump and thermostat first as a test.
