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I'd keep that classic going if I were you. One of the best boilers ever made. Ted

A perfect seal holds more than 30 feet of water, but then again I'm basing that on experience and not theory/google.

No idea how I've been bunging systems and cutting pipes for the last 15 years then? Last week I changed a trv on the ground floor of a three storey town house and the water didn't come rushing out. Maybe I'm a Jedi? Maybe it's physics. Get a straw, put it in a pint of water, put your thumb...

It's all down to marketing. A few years ago Vaillant and Worsc boilers were quality products that had great build quality. The modern day boilers they are producing now are poor reflections on their previous models with a lot of plastic inside and aluminium heat exchanges, however due to...

CT1 superglue

Pretty much. The only other step I make is when you've done all the rads, open the drain on the magnacleanse, close one of the valves on the magnaclean fitting to force the mains water from the filling loop back through each radiator in turn. You'll know it's working when that rad goes cold...

A bypass is handy to keep the minimum flow going through the boiler.

Yep. Done 100's like it. Ted

Your way will be fine as long as you keep the pipes as low as possible in the loft. Ted

Sometimes the Glowworms can get noisy after a couple of months (trust me I've fitted 100's) it's a simple fix for a boiler engineer. The thing will be under guarantee anyway. Ted

Or lower the kw all for free

You need to lower the KW rating on the boiler. It is all in the instructions which hopefully you have or they are available online from Glowworm. I would suggest start at 10kw and see how that goes. Ted

How big is the house? 30kw open vented is a large boiler. Could be over sized. Ted

Alright pal? It's ted

A 5kw rad? What size is it?

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Just run it and see what happens. Check you've got water in the small header tank in the loft. If it pops again you could have circulation issues. Turn the boiler stat down to 3 or 4. Ted

Check the over heat hasn't popped. Small recessed button under the boiler. Ted

They didn't. All new boilers must be condensing, not combi. Very common confusion. My advice stands stil. Do all the pipework and rads and keep that boiler as long a possible. Your choice on what you do with the cylinder. Ted

You could keep the current boiler, and just redo the pipe work? Personally I'd upgrade the cylinder to an unvented one (depending on if your water supply is suitable) at the same time. Plus get the system cleaned and add a magnetic filter. Keep the current boiler going as long as possible...