Hi Jim and BBP. Welcome to the party & thanks for the input. Its reassuring to hear that although my boiler and system design has obvious problems things are likely salvageable. I will let everyone know how my project works out. Hopefully i can address some of the issues this weekend. Although, with Halloween festivities it may be difficult to find too much time. BBP, i'm glad you still hang around and post.
Morgan, sorry to hear you suspect I am taking advantage of those helping me. Maybe one of the "pro only" sites would be a better fit for you. I don't mean that to be a judgmental comment, I also work in a field with a high number of DIY folks and believe me, I understand your frustration. The absolute last thing that would be healthy for me would be to spend my free time reviewing their misguided internet submissions. My posts would likely be interpreted by the recipient as much more pointed than yours are here. At times this has been a frustrating and humbling experience and I have started to make a much more significant effort to be patient with the frustrating DIY folks I encounter at work. Have a great weekend everyone and thanks again for your contributions.