I think I may have it, although it could still be the pump, and it was acting just like an old fashioned vapor lock. First it has been running in the same configuration since '06 with zero problems, but in northern California and never really stressed by heat. Second it all happened after a forced long idle and slow move through some back road repair, and it was really hot. No motor overheating but I have a good cooling system and
oil cooler and that has never been a problem.
However, once I got it home and it cooled down, it's all back to what was normal, runs fine again. The pump sounds normal again and the pressure is normal via the gauge again.
So, I think it may be the aluminum fuel filter being heated up by the header, with little or no air flow that day. Maybe it was pushing vapor out of the filter under pressure to the fuel rails and when I could get it to run it just kept heating up again and he comes the surge and die deal. Not sure but the filter is only 3 inches or so away from the header tube and the line runs right along there too.
Could still be the pump because I don't know why it would change noises and not pump up pressure when it's hot but time will tell.
The picture is of the filter by the header tube on the driver side. Years of being OK but clearly not a good idea for Texas heat no matter what.
Thanks for the all the info, great educational stuff for everybody.