Time for the aluminum thermostat housing. Noticed this leak the other day.
Ordering parts from Rock Auto
Thermostat Housing 39.89
Thermostat 20.79
By Pass Hose 2.22

I'll have to find someone to bend the 8mm wrench for me.

 

I used this method suggested by one of the members (sorry no credit, I forgot who it was):
Break off the old thermostat housing using a hammer, stuff a rag down to keep small pieces out of water passages. Trim with cold chisel until you can unscrew back bolts.
Use socket head screws at back of new housing. It is necessary to use a thin screwdriver to get them most of the way down, but you can finish with a ball hex drive. I bought the long set from Harbor Freight.

 

You do not need to bend a wrench, use a rachet with a 10" extension and 8mm crows foot

 

What I did on mine was to buy a siphon pump and drain the fluid below the cooling tower. Then just used my bernzomatic propand torch and made my own tool. The problem with the 8mm crows foot was I could not find one to buy loose or in a set, most sets I found start at 10mm. I did not want to chase down the Matco truck to buy one crows foot.

Just another way of doing the same thing.

 

I thought about the crows foot but I haven't looked for one out here.

 

Harbor Freight has them, it is the only time I have used them in the 3+ yrs I have owned them.

 

Installed the aluminum housing today. What a PITA! The back bolts were a nightmare. Ended up breaking the housing to get them out.
One bolt on the thermostat cover was frozen in the brass insert. Went to Home Depot to get a bolt. Had to use a bolt & washer.They didn't have the proper bolt. I'll have tp keep a look out for one.
All told a 3 hr job turned into a 5 hours. But it is done!
I noticed that the outlet pipe had broken on the end. There was enough to attach and clamp the bypass hose. Any one know if this is available in aluminum or are we stuck with plastic?