I have not replaced my gas cap. I've had a vented cap all along. I also have a dedicated vent for the tank. I have not checked to see if it is clogged. You do bring up an interesting point though. I've recently had some tank work done: I had the fuel pickup changed so it draws fuel from the bottom of the tank (the tank was cleaned and resealed) and baffles were added around the new pickup. I don't know if any of this could be part of the problem.
As far as filters go, on the original Pro Flow they did not have a filter prior to the pump, only one after the pump. With the new pump I did add a filter, but like you said, I added small one to prevent problems drawing fuel.
My new pump is installed in essentially the same place as the old one. The original Pro Flow pump was mounted inside the frame rail (passenger side) in my 1970 Chevelle. The new pump is quite a bit larger. I had to mount it outside the frame rail. As I mentioned in my original post, I did not wrap the second pump with any heat wrap. It's about a foot or so away from the exhaust pipe. The current pump is completely wrapped and I also shielded the exhaust pipe where it is closest to the pump. On the road the pump should get quite a bit of cooling air since it is now outside the frame rail. However, the last stall I experienced was while I was on the freeway, going about 65, with an ambient temp of about 75-80.
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