Problem Solved!
Thanks for all the help and ideas. Among lots of other issues, the main problem seems to have been the fuel pump! After researching all the options I went with an external pump for convenience, the Carter P74017, spec'd at 10.3-14 PSI, 23 GPH. Yager stopped by on his way to DPG this afternoon and after fooling with it for awhile we determined that the 8 fluctuating psi it was putting out was not enough. Actually by the time we swapped pumps it was putting out more like 6 PSI. I think it had been going bad and was getting worse, and this was a brand new NAPA pump! We swapped in an E7001, spec'd at 17 PSI, 28 GPH, in tank pump I had laying around and after the computer did some learning we were ideling along fine at a steady 12 PSI! I have learned a lot during all this and have more to learn but I never thought a few PSI would make that much difference in a TBI system! Special thanks to 3DCrawler for some of the most knowledgable and informative TBI info I received along with a good price on the parts!