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What a good puzzle! When the thermostat opens, the overflow bottle empties (!) and then fills up again. That makes no sense at all. I can understand it overflowing due too much fluid, did that once on my 220 by filling after startup. Sucking the bottle dry is an indication of a large bubble in the upper hose.
You are correct in assuming that all of the air in the engine passageways is now filled with fluid. Same with the radiator, otherwise you would never have poured in 2 gallons. You did take the plastic cover off the bottom radiator port :)
Klaus
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1967 220 belonging to C.A. lives on
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