What happened with the EGR valve test? Does it still stall with the EGR vacuum line disconnected? Does it start hard or start right up after it stalls?
You mentioned your clutch pedal clicking. Does it shift hard?
You may also want to make sure that your plug wires are secure. If one is loose, it could be moving forward as you brake causing it to arc on a header.
Are you running your A/C? Does it matter if your A/C is on or off?
Fuel pressure will only affect air/fuel ratio until the computer adapts. 45 isn't all that high and dialing it back wasn't really necessary, but getting a new FPR probably eliminates that as a potential problem. Sorry, it's just a pet peeve with me. Especially if the guy at the dyno leads you to believe that you can adjust your air/fuel ratio with an adjustable FPR.
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