So I think I have my fuel pressure issue figured out. More conversion issues.
Last night I pulled the return off the hard line at the tank. I ran a hose from the hard line to the fuel filler and fuel pressure was good. I was able to get the adjustable regulator set properly. Also didn't have a leak.
I used an inspection mirror and looked for kinks in the return hose at the tank and couldn't find any sign of an issue. Called it a night. This morning I started thinking about the sending unit. What it boils down to is I have the return line on the vent for the sender. Here's why.
Sending unit for a TBI pickup with the saddle tanks like I have on the 89 crew cab:
And this is the carb sender I'm using for the external pump:
The thing to note is the return & vent lines. On the TBI sender they are 5/16" return and 1/4" vent. On the carb sender it reversed! I could have been tipped off when I tried to conned the vent hose from the sender to the existing hard line on the frame. I had to use a barbed adapter to go from 1/4" hose to 5/16" hose in order to get the hose to fit the factory vent line at the frame.
The fuel pressure is running high because it's trying to push the fuel thru that apparatus on the end of the vent line in the sender. I assume it's there to keep fuel out of the vent in a roll over type situation; probably not meant to flow much. In hindsight I can actually here it. I had noticed when I turn the key and the fuel pump comes on there was a lot of flow noise at the tank. I thought it seemed a little odd.
So now I'm debating about if a 1/4" return is sufficient. My Pro-Flow only needs 43psi, so it's not pushing a ton of fuel thru. Part of me feels like it would probably be fine. But the other part of me thinks about how the factory TBI is set up with 5/16" return. Aggravating thing is, I could easily swap the lines at the frame and be good to go. I could even do that and say that in the near future I'll drop the tank and do it up right, but if it worked I'd probably never touch it again.
In order to get 5/16" for the return, I'm not sure what would be the best approach. I could take the do-hicky off the vent so the existing 5/16" would flow freely, but then I would need to figure out a way to put the do-hicky on the 1/4" line. May I could use some hose and barbed adapters. Or abandon the 1/4" line on the sender and make up something with a bulkhead fitting.