I had my money on the return line causing problems, but your last test ruled that out. Might be interesting to get a gauge on the supply side of the regulator to see if you are actually getting a big spike in pressure when first turned on that the regulator can't handle. If those pressures look decent, then I'm with the guys suggesting something momentarily sticking in the regulator.
Also surprised you only have a half pound residual pressure. I'm running 10-AN hose for a return and residual is a little over 2-1/2 pounds with the Mallory 250 pump.
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Mick Batson
1967 original owner Tyro Blue/black top 4-speed HO GTO with all the original parts stored safely away -- 1965 2+2 survivor AC auto -- 1965 Catalina Safari Wagon.
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