It's been running just fine last night & today. We loaded it to about 6.5 kw and it cruised right on. As always, after one of it's "incidents" we are watching it like a hawk, but I'm confident our only problems for the next month or two are the freeze plugs springing more leaks. Amazingly, the best solution for the moment is to clean the rusty leak very well and run a bead of that UV curing adhesive over the hole. However, the worst one by far was in the head, so we could reach it when the head was off, and replace it.
I had assumed the water channels were equally corroded, but while replacing the thermostat housing I was able to inspect that area and it looked surprisingly good. That could make a big difference on our decision to rebuild or replace it. Either way, it's going to be a busy hurricane season. Anybody got a sky hook we could borrow to get it outta the engine room and off the boat?