[RustyWa]

The Haynes manual states "Heat a pan of water to 65-70 deg C" The thermostat I received from Pelican was stamped 85-90 dec C.

When I used the cooler temps stated in the Haynes book, I didn't get much thermal expansion. Everything worked to spec when I bumped up the temps stamped on the thermostat.

It's been awhile, but I think I had more expansion than what you state. The thermostat was nice and tight when cold. Just like the photo 4.1 in the Haynes book.