Ok, since no-one has mentioned these Ill point them out... I know you say "all" upgrades etc.. have been done, but sometimes people overlook a few of these.
Is there a gap between the sides of the radatior and the core support? Or is there a big hole in the core support next to the radiator for who knows what reason? If so block it off with some sanitary looking sheetmetal, I like aluminum with a little clear sprayed on it, but stainless is nice too. These holes allow hot air that has just come out of the radiator to circle back around and work thru it again... reducing cooling ability. You want all the cool air that enters thru the grill to go thru the radiator.(and/or the oil cooler, trans cooler, etc...)
Does the car have an oil cooler? If not it could help, it pulls heat out of the motor, it also increases the oil capacity, and if plumbed right, gives a great spot to drain from that is lower than the filter. (so it doesnt piss all over the steering / suspension when you pull it off)
Have you tried Redline Water Wetter? It worked in my 5.0 for about a 10 degree drop all the time.
Is there a fan shroud? If not get / make one. It will help the fan work MUCH, M-U-C-H better. Also if you run an electric, make sure there is no gap between the fan and the radiator (or make a shroud so the fan can draw thru the whole surface area of the radiator).
You may also want to up the pressure of the cap a few degrees (3-4) Sometimes guys run low pressure caps (like 7lbs) but dont realize that while the water in the radiator is ok, the water can be boiling inside the heads/block creating overheating problems. (if i remember right) You gain about 4 degrees of boil over protection for every lb of pressure. If your at 7 or even 9lbs and go to 12 or 16 on the cap, thats 20-30 degrees of safety net against a roadside nightmare.... Now I wouldnt go too crazy with it like a 24lb cap, cuz I think (imho) this leads to changing alott of waterpumps, etc... due to leaks.
Also ceramic coated or thermo-tec wrapped headers / manifolds can cut under hood temps quite a bit. (on mine you could feel the difference when you open the hood, i dont know how much that was... may-be 20-30 degrees)
But you could see about a needle width drop in engine temps (maybe 4-5 degrees...) in hot, stop-n-go driving.
By reducing the temp under the hood, you allow the engine and radiator to give off more heat in the same period of time, because the diff between their temp and the air temp around them is greater. A cowl hood (or louvers, or whatever) can also help with this.
Again just my .02, hope some of it helps.
Dave-
