We used the Hughes kit as well..... still hate the design... I tried to slowly close off the vacuum leak using my finger, say over 10-12 seconds. as soon as i fully closed it off, the engine died. I hate to throw parts at it. I also hate to pull the intake again.....but it's no good the way it is. maybe some more backtracking this evening will shed some light on the issue.
1985 Crew Cab W250 4x4 - daily driver, 5.9 magnum, carbed and distributor, A-518 and NP205
2002 3500 extended cab, 4x4, Cummins and 6 speed
1997 Ram 2500 5.9 with 35 Boggers - Mud Racer
1993 Dakota 4x4, Dana 60's front and rear - work in progress
1992 Dakota 2wd short bed, awaiting 440 swap
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