Long story short, I built a larger PS reservoir that is internally baffled and uses a vented cap. (For reference the stock cap allows system to get up to 7psi..according to TurnOne).
I'm using a new -6AN PTFE lined SS braided hose to the rack from the pump. Then new 3/8" line from rack to cooler and back to reservoir. Pump is a used PSC rebuilt unit I bought from a forum member (I also have a "new" PSC pump I can use).
I don't see any leaks from any fittings and pretty sure I bled the system. Have been driving on it for a week on the street. The pump will get pretty loud after a 15min back road drive on street tires with no high RPM situations. After such a drive I get the following bubbles in the reservoir:
B&M Cooler location. Has 1/2" inlet/outlets. Used 1/2" NPT male to -6AN male adapter 90* to 3/8" barb.
I am using cheap Autozone PS fluid...I did so to check for leaks after installing everything so I didn't waste good fluid. Car will get Redline PS fluid. I'm not sure if this is "normal" or not since I was never able to see inside the stock reservoir. Steering feel is "normal".
My next step will be to bypass the cooler and see if aeration is still there using a double sided 3/8" barb fitting to join hoses.
Any other thoughts/suggestions?