From my understanding and after showing the rad to two Rad repair shops in town here and telling them the story, they both told me that its just a defective rad that the O-ring didn't seal properly between the plastic top and aluminum core when it was crimped together. They both said that’s typically a warranty situation and could not be caused by over pressurizing as the rap cap would let that pressure blow by. And would not be caused by a poor install.
So Steven I really hope you reconsider your take now that you have all the facts and some pictures and help a poor Pajero owner out...I don’t have the extra $350 to throw at it again because of a defective part, which I understand can happen in this day and age with mass produced products. And I would also understand if it was an electrical part as it is common place that there is no warranty on them as they can be shorted out easily.
I'm also hoping you help me out as I'm currently rebuilding that L300 I bought and will need many parts, but will not buy any from you if there is no after purchase warranty or customer service.
Please help me out!

Joe