99 cougars are return. He said he has a fuel pressure regulator which aren't found on returnless systems. He has 42's and a large enough maf.
I did have a similar issue once. One of the fittings on the pump wasn't seated right. This was before the focus SVT pump was available. I had to rig a Walbro. It sprayed gas back into the tank at WOT but the pressure only got too low when I exceeded 300 hp.