Well I pulled the fuel pump and checked the push rod and compared it to the new rod I just got from Mancini. The rod is the exact same length as the new one with no wear I can discern. I am guessing a worn rod isn't my issue. :-(

If this isn't vapor lock, I am open to suggestions on what else to check...

As far as the hemi/440-6 setup, how did the factory hook all that up? Was there a hard line from the pump outlet to the vapor separator inlet? Did you just use a barb on the outlet and run rubber line to the separator? Where does that little tab on the vapor separator mount on the engine?

Thanks!