New Delphi pump, old pump, Denso pump
Figured I'd post the final result here. Ordered a Delphi CFE 0486 which is a direct replacement for the factory 62 pump, $100 from Napa. It is indentical, however unfortunately the box label says "Made in China". I decided I'd test it before mounting it in the tank, and it worked fine pumping water out of a 5 gallon bucket.
Mounted it in the tank, installed the tank, jumped the test pins to check pressure, and got 50 psi. Started the truck, and as soon as I blipped the throttle, again the pressure shot to the mechanical extreme on the gauge and the new pump started squealing. So I realized the noise wasn't really a pump issue. I found an old regulator in my spares bin, popped that in, and then the gauge showed 40psi at idle. When I blipped the throttle, it would bump up around 45psi and then regulate back to 40. And no noise. Test drive confirmed, no pump noise, maintained correct pressure on the gauge.
So the noise was a regulator issue. However, I am not sure if the Denso pump may have damaged the original regulator or not. I didn't have a pressure test adaptor before I changed the pump to know what the original regulator did prior to the Denso pump - however the truck always ran fine. Last summer I had swapped those to regulators to check something else and they both performed the same. So ... I really don't know if the higher pressure pump caused this issue or not. The real test would be to re-install the Denso with the "newer" regulator, but that's a bit of unnessesarry work at this point and I suppose I run the risk of damaging the working regulator. And those aren't cheap anymore.
Anyway, at least I have the tank drop / fuel pump replacement procedure down pretty well. So I'll just install the Denso pump when it's needed. Thx for the feedback in the thread, always nice to have other opinions to consider.
Gauge installed with LCE adaptor 1093076
(link)
Final pressure at idle: