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Bob, Mopar filters are made by whoever gave them the cheapest bid this week. I'd run Wix (or NAPA since Wix makes them). No inconsistency with them. Since it's easy to do with a BB I'd try a stock pressure spring shimmed to give you the hot pressure your after. It is a weaker spring so it might...

I would think a lighter relief spring should do the trick as it stays closed until it reaches a predetermined pressure then opens up. That shouldn't affect idle pressure

There are huge variances in cars even with the same WB. My 68 Cuda FB is 3470 without me in it. With me it's 3640. It's a SB 904/8-3/4 car and the only option is power steering and a mild stereo system (about 20 lbs)

Hum... They must have went to crap cause I used a set on a 418 build that sat nice and flat unlike the ones Mike pictured. Used a pretty stout solid cam and 350 spring pressure over the nose and 4-1/2 yrs. later their still going strong.

I'd check the firing order. If you've got 2 plug wires switched around it can ping and pop through the exhaust.

Even though it is a 440 it is in a real heavy car with airplane gears so you need to keep as much low end torque as possible. That said I'd probably go with a street dominator. Nice middle of the road manifold. It's a single plane but doesn't have huge runners or plenum so it's still got decent...

Even with a re-curved centrifgual advance that gives maximum power at WOT most street driven cars will benefit from a properly set up vacuum advance because at part throttle (light load) when the vacuum advance comes in more total timing can be used which helps fuel mileage and keep plugs...