Is the radiator corroded? A heat exchanger will lose effectiveness as the material corrodes. Don't sweat the overflow. Let it do its thing and overflow. It will only do so until it has the proper amount of coolant, then it'll only expand up to (not beyond) the point of overflow. I'm actually a little confused as to why there would be a vent cap if there's an overflow tube. I'm not familiar with this particular model.
Whatever it is, it doesn't seem like a coolant flow issue, given the water circuit work you've done. It seems like poor heat transfer. Are you sure when you clean the radiator you didn't bend the fins, thus preventing proper through flow of air? Also, sometimes the dust can really pack into a heat exchanger and you'd be shocked at how solid it becomes. I like to clean mine by using compressed air blowing from back to front, opposite the direction that the radiator got dirty in the first place, rather than front to back, which just tends to jam it in tighter.
Keep us posted.