Sorry, Andy there is no "ah-ha " moment coming in form of a comment, thats why you don't have 3 guys chiming in, saying "all you have to do is this..."
This is the part where if you have the money, you have to pay to have someone figure it out, or if you have been around these cars long enough you start solving problems and eliminating possible issues, and then narrow it down. The "ah-ha" moment will actually come from you , when you solve it.
We can help guide you in the right direction, based on your investigation, but without being in front of the car hearing what it is doing and how it responds to different tweaks, it is all a shot in the dark for us.
So to put you in the best possible scenario, solve the issues you know about first, then go from there.
It sounds like a fuel issue initially to me, so start by fixing the sender so it is sealed in the tank properly. Hell you may pull the sender out and realize the pickup is blocked, or functioning incorrectly. ( I would say small chance, but you have to fix the seal any ways, so might as well fix the seal and check off the seal and sender as possible issues). And thats the thing* you have to start eliminating possibilities. It is great to find the problem right away first try, but even the mechanics have to use a process of elimination on the tough fixes.
Good luck, and keep us (me) up to date .