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The overflow valve is actually the banjo bolt that threads into the fuel return port for the fuel return hose on the side of the pump.

I haven't gone back to read the rest of this thread. Been a long time since I looked at it. I was thinking you were doing that to get more power, but now it seems like you must just be doing it for testing purposes. My apologies.

The barrel to body seals in that pump won't hold 300 psi. Just to be clear; you're talking about feeding fuel to the pump inlet at 300 psi in oder to maximize fuel intake to each plunger when the spill port opens, correct?

If you haven't done so already, replace the overflow valve on the pump. They are notorious for failing and causing low fuel manifold pressure. All it is is a banjo bolt with a spring and ball bearing inside. The spring breaks or the ball gets pitted and they leak pressure by. Look for a Torktec...

The intercooler is going to be what makes the biggest difference for you. If you run an HX50, or compound turbo setup, you will likely want to install some good head studs. It may have head studs already, not sure because I've not had a valve cover off of an 8.3 yet, but even if it does, I would...

Well, if it was a multifuel you probably would have melted a piston... but I bet you at least melted some small pockmarks into the piston tops if you hit that temp for more than a couple of seconds.