Eureka I think I got it! So after all the other work. I finaly worked up enough courage to switch on the A/C. Seams to work fine... Right.... So i poke a look through the grill and notice that the A/C Electric fan is only spinning slowly as the main fan is draging air through the radiator. So I poke a stick into the blades, sure enough its not powered up. So after some troubleshooting I confirm its toast. But its free spinning, no frozeen up. Anyhow I replaced it with an AutoZone $75 special. It works great. I disasembled the old fan and it was completely cooked inside, brusshes toast and melted.

So since the first thime this thing overheated several years ago the A/C was in use my guess is that it has been toasted all this time and noone (Including me) ever bothered to check ye old A/C fan.... Wow... I can not believe it. I'm guessing that all of the damage to the cooling system and leaks and broken fittings were all caused by the overheats due to the bad fan.

Thank you all for the help. - BTW: The Barsleak Block Sealer solved the heater core smell... Worked real good.