Matt, check out your O2 sensor. Remember mine?

His is virtually brand new. AC Delco. Can't rule it out regardless, but the odds are very low.

Why do you need to extend the gauge to know what pressure at WOT?
The fuel pump produces 60 psi
When the vacuum drops to 0 (ie.disconnecting the vacuum port on the regulator) then the fuel pressure should be at maximum. For me it'* 56 psi.
With the car idling the vacuum should be highest and with the vacuum connected, the regulator should be throttling the pressure to its lowest setting. For me it'* 46 psi.

With my adjustable regulator I have it set 4 psi above what it was stock.

Just thinking it could have melted...

Oh, gotcha. From the extreme exhaust temps. Not a bad idea.

true enough, i will take a peak at her.

The o2 sensor that I took out of my car last fall was very melted, and the o2 I took out 3 weeks ago was melted also, but not nearly as much as the first.
Haven't had much driving since.

Definitely don't rule out the melted o2'* -I'd never experienced that before, but now having seen 2 in the past 6 months I definitely suggest you check it if there is reason to.

Just thought to mention a small side benefit to changing to aftermarket headers is the O2 sensor is relocated another foot further down the exhaust in a much cooler location. Most kits include the O2 sensor extension harness.
When these engines make big power, they make big heat. Darn combustion engines aren't very efficient. :?

lol no such thing as headers for my application lol
all ive heard is..93 SSEi? haha my grandparents owned one of those, headers, nope sorry
lol

Having factory origninal 2.25" exhaust, the SC/SLE'* are more prone to this perhaps. In todays case, no that you've upgraded your exhaust to 2.5", I know what your problem is.

The 94/95 Gen3 SC and TB together produce too much flow. And there are too many factory restrictions.

I'm beginning to think that the LIM and EM porting should be a requirement on 94/95 L67'* before a pulley.