Ken - I just had a thought....
It actually appears that the hollowed out part of this has actually been filled with metal-set or some sort of epoxy...... I realised this looking at the new cover.
I would think that maybe this would actually restrict the flow a GREAT deal ...
It would also rely quite heavily on the small gap between the inlet pipe on the top (from radiators) and the pump cavity.
Maybe, just maybe the pressure from the pump is actually back-flowing UP and into the supply (from radiators) line?
Buy that cover - and all will be good..... surely !