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John,
Put the word out and also try some of the vendors. The cap fitment is important and I think your trying one variable at a time is a good approach. I seem to remember one of the vendors back about 15-18 years ago mentioning that the stock cap fitment was never very good and that the aftermarket caps don't fit stock very well.
I believe the challenge is that the expansion tank's neck is longer than a standard American radiator. Since the neck is longer there's effectively less pressure on the spring and the cap will open at less pressure than 16PSI, perhaps half that (??). I already trued the mating surface of the tank to assure a good seal.

Thanks
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