Yes start your system with minimal KOH in it. Then run it, slowly raise your KOH concentration to get your desired amp draw. Make sure it as hot as its going to get first.
Pressure is caused from resistance period. So any where you have small opening that would be restrictive to flow for your gas and electrolyte flow you will have pressure. Make sure the gas outlet is not obstructed. The crack looks like it may be due to over tightening the hose barb, or maybe it cracked when it was drilled and the added pressure may have finished the job
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