No puking, the electric fans can still come on with the engine shut off which keeps temps under control. Even with the water pump stopped, it cools down (while the stat is open) via thermosiphoning and the fan.

I have a catch can and a "normal" radiator cap. No recovery system. But the only time it got about half a cup in it was when I filled the radiator to the very top instead of 1" down.

I've really never had any trouble getting the air out of any cooling system I've drained and filled. I think the key is just to fill slowly and give the air a chance to bubble to the top (and a vent hole in the stat helps too).

Just removed the water pump - unfortunately I did use the right one (8 vanes). So the high-output one may not fix anything. At which point I may admit defeat and either buy a better radiator (like the one suggested above). Or just live with the slightly-higher temps!