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Could the water test be masking something? Meaning, that water flows OK but oil may not due to much greater viscosity.
I noticed on my recent install that once the thermo opens a wet cooler will begin to steam. Maybe you can build this into your test.
Perhaps under idle there's not enough flow to push oil through the entire cooler since it goes in the inlet and trickles down the tubes/fins to the lower tank and out the fitting. If the oil is just trickling in then it will flow down the first tubes/fins and not reach those at the opposite end of the cooler. Could there be a problem with your thermo not opening all the way and thus not flowing enough oil?
In my car when I come in from a run and I am sitting idling I can hear the oil rushing through the outside lines.
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'83 SC
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