I have removed the thermostat housing from my engine and found the outlet pipe to the heat exchanger and housing almost completely blocked by a large amount of a crystalline gel like substance.Any ideas what this could be.
I understand correctly that this is between engine and heat exchanger of an indirectly cooled engine?
Have you used any additives in the cooling system apart from presumably an antifreeze?
I guess you are concerned that the whole system is bunged up.
Can you try to see if a little will dissolve in some dilute acid (vinegar, an acid descaler, or a hydrochloric acid based brick cleaner for example), and if there is any visible effervescence? Warm if nothing happens when cold.