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Wouldn't the idle issue be a droop screw adjustment and NOT a main screw adjustment?

Have you tried adjusting the droop screw? My only issue with recommending this is it previously ran well at the current droop setting. But, that would seem to be the best way to even out the idle issue until you find the culprit. I think you're sucking air somewhere upstream of the HH. Edit...

Gimp knows better than me by a long shot. Consider me paranoid.

You have done your homework from the sounds of it. http://www.steelsoldiers.com/deuce/69241-removing-rebuilding-reinstalling-hydraulic-head.html This is the best thread I have found for detail HH pictures and issues. It sounds like she lost the button, then lost prime at least. It might be...

#8 has me more concerned than #10... What I'm getting is, the button fell off the HH, and there seems to be rust inside the head on ports 6 and 2... but you tested port 6 and got fuel out of it at the injector.. Am I reading that right?