Little update on my progress.
Installed a real sender in place of the oil pressure switch, and bypassed resistor on back of panel. Checked pressure with a known good working gauge, 40psi with engine at about 140-150 degrees. It had cooled off for a while. Seems to be working right. I know it's not a replacement for a real gauge, but better than nothing.
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Also did the heater core diverter mod today. I bet this makes a big difference with the AC in this truck. I did the same mod in my 01 superduty about 10 years ago. Big improvement. Looks almost like it belongs there.
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While I had the gauge cluster out I discovered someone had pulled the ABS light. Now my Cruise Control not working makes more sense. The harness connector on the vehicle speed sensor is held on with a zip tie. Speedo works though, so not sure if that is the first place to look. The recall has been done and the master cylinder is new, looks like the pressure switch is new also. Will have to spend some time with the troubleshooting guide in the tech section to figure it out. The clock spring checks out OK, all the brake bulbs work, but the 3rd brake light is a bit dim. Will probably swap that out just in case. Not sure how sensitive the system is to that stuff. Would be really nice to get it working right. Also, is there a Cruise Control Light on the dash somewhere? I couldn't find it... Definitely have the module and steering wheel buttons though.
Ordered a 3" down pipe 4" straight exhaust today for a 94-97 powerstroke. Going to mod the turbo exhaust housing for a 3" band clamp and re-angle the end of the down pipe. Will probably do this at work on the weekend. I think I'll pull the bed to fix the pickups on the tanks, should make the exhaust install easier. Basically have a full fab shop at work, and the owner is cool about me coming in on the weekend to work on something. I sold the Chevy, so this truck is my only vehicle now. Going to have to plan carefully!
Overall it's been running great. Put about 500 miles on it, averaging just shy of 16mpg overall, almost all on the streets. Hard to complain about that.