Talked with gaboon to sort some ideas out since nothing seemed logical. What's one thing that could leak enough coolant (about a gallon a day or 35 miles) without creating a noticeable puddle, no coolant in the engine, boiling water, no pressure in the system, one of the few places that aren't recently new and rather difficult to see........then it occurred to me....
The heater bypass hose round around cylinder 6 where it meets the head. This pic is of the side facing the firewall.
Why didn't I see a puddle? Burned off on the EGR plate slow enough not to notice and traveled in 10 different directions spacing out enough to not create any puddle, and large enough to leak that amount of coolant and allow no pressure in the system. Also, because I was using distilled water primarily so long, a drip here and there would dry up in no time. Its the one key hose I didn't replace during my last big issue (rear timing cover gasket). I've been so focused on the rad I ignored a common place that I should've looked in the first place. Must have been the extra pressure from the 1J rad cap that made it go.