Too small, its a 1" inch ram the 1.5 is the size of the ram it-self the 1" is the shaft.
He's running the same SurplusCenter ram that 90% of the hydro-assist guys on this forum run, including myself. There's nothing wrong with that ram, in fact that's the size I would always choose for a street-driven rig.
I also drilled my pump to 5/32", didn't modify the spring, but I did notch the valve thing...I went to that RedneckRam site and did all the mods that increase flow, but didn't mess with pressure at all (didn't need to and didn't think it was the best idea). Honestly, I can't think of how increasing flow would do anything but prevent what you're describing. What you're describing sounds like intermittent flow to me...just can't think of why it would be speed related. Either that, or maybe it's something to do with the pressure valve thing inside the box, but that doesn't make much sense if it was working fine the other day.
My truck drives excellent. Much better than it ever has since I owned it, even on the interstate. The only difference I can think of between your setup and mine is the fittings. I used 3/8" NPT fittings on my steering box after reading a lot of threads about it on Pirate. Everyone over there said that 3/8" was borderline too small, and that 1/4" was a bad idea.
Mine has noticeable feedback/return-to-center for about the first half of the rotation back to straight when I'm driving around corners in the neighborhood. The 16.5" wide Pitbulls had the feedback a little vague before I ever put the assist on though, so I can't really say what exactly is going on there...I've never really done an alignment either so who knows. I will say that the feedback is apparent enough that my girlfriend (who is a typical woman who thinks it's scary to drive, etc) did not notice any weird handling issues even when I asked her if she thought the steering was vague.
I'm not quite able to wrap my head around why yours would be behaving that way, even with a bottleneck at the fittings...would help if I was there and could actually see it for myself of course.
Where is your box tapped? Is this behavior RPM-related at all?
Do you have a variable sector shaft? I don't think I have ever knowingly drove with a non-variable, I'm sure it's noticeable though if you're actually paying attention. I can't think of why it would make a difference here but it seems like the idea is worth exploring
Are you 100% sure there's no air in that ram or somewhere else?