Going back to the beginning Wes & any number of others have told y'all to check a number of things....there is no indication any of this has been done.The radiator never boils over. I have removed the thermostat, the radiator has been cleaned and tested, all new hoses, water pump rebuilt, new temperature gauge. Has anyone else experienced this problem?
Water pumps may leak & don't just fail like you are suggesting.started it up and the lower hose again begain to get hot right near the pump. I stopped it before it overflowed again. could a complete pump failure cause this?
Systems that have been overfilled will always overflow when they heat up the first time....then they will maintain the level after overflowing unless folk insist on topping up all the time.
The lower part of the cooling system including hose will get warm/hot before the thermostat opens & allows flow.
One must understand coolant flows by convection [even without a pump] from the normally coldest part of the system [bottom radiator tank] through the engine block, through the thermostat [if it is open] out through the top hose & into the radiator again [top tank].
The coolant cools & flows through the radiator to the bottom tank then the cycle starts all over again.
You tell us what happens to the coolant when the thermostat is closed?
First thing to do is check the gauge is reading correctly & that was what I am sure was recommended back @ the beginning of the thread.
One suggestion here is to post what y'all did, with the results as done, then no one needs to go round in circles.

