Motor was a half hp freebie. Pretty old unit. I didnt have a gage, only cranked the pressure up to get the fuge spinning and then left it at that setting. I do have a gage to install.
Gauge is an absolute must. You'll feel "spool" of the fuge as low as 45 psi, but thats half the pressure you need to run it at. 85-90psi is right where you want to be to do anything. At 90 psi you'll know its spinning. Solid mounted like yours is, it'll hum BIG TIME. The rotor is spinning about 10k rpms, and when you spool it down it'll sound like a jet engine coming to a stop
I'm pretty certain your problem isn't related to the fuge. They are super basic with very few moving parts. The only way you'll have fuge problems is if the feed stick (can't think of the real name right now, but its the rod the rotor slides down on) is clogged, or if your two nozzle/jets are clogged. I've clogged both before w/ a lil piece of thread tape (hate the crap dont use it) all you have to do to get it out is squirt a little brake cleaner thru them w/ the plastic tube the bottle came with.
If your motor crapped out and you think it was in good shape your pump is too much for that motor to spin. ICBW, but it seems like the guys using power steering pumps have to use larger electric motors than the ones that use the gear pumps designed for these "kits" They must just need more "juice". FWIW up until a week ago when I "upgraded" to a monstrous Oberdorfer pump w/ 3/4 hp motor, I had a 1/2 motor w/ carbonator pump. It powered my 108 gph PABiodiesel fuge with ease (i.e. it could easily power a 108 + a 65)
First things first, don't screw with it anymore until you get that pressure guage inline, post pump.
If your black o-ring at the base of the rotor is squirtin out on you, it's either that you tightened the nut down too tight (it just needs to be snug)
or you might've gotten the wrong o-ring. I've not had that happen to me, but can't forsee how that could happen any other way. By accident I've had my fuge spinning w/ 140 psi for a short period, and it didn't spit out the o ring.
Edit: come to think of it, no way you got the wrong o-ring. the next size up they sell is the 108 gph. the rotor size is substantially bigger than the 65gph one. The 108 oring would fall right off the 65 gph fuge.