Oil line plug/ low oil pressure on cold starts

I wouldn't run 15/40. I'd stick with 10/30.
Exactly.
If anything, on a cold start one wants a lower 'W' grade and a lower pour point. Same for any time an engine is used for a lot of short drives where the oil doesn't get up to temperature.

I'd also be looking in the used filter to see if the anti-drainback 'valve' was blown back or in some other ways has failed.

Clacking on a hydraulic lifter says to me they're not getting filled right away.