The EGR should not be opening, it starts cycling open-closed around 55mph according to the EGR temp sensor diagnostics test procedure. Maybe a little earlier but definitely not open during start up.

You say it gets harder to crank, which is different than hard to start. If it cranks slower you have a power supply or starter issue. If it's hard to start and spinning normal its probably the fuel pressure up sensor, one of the sensors on the thermostat housing is an input for the fuel pressure up vsv and there is a TSB that has this switch changed to a different temp.. You can disconnect the vacuum to the regulator when its hot and not starting and see if that nakes it start.

You might want to look at your hot cylinder compression also, if it seems not to be firing and is spinning a little faster than it does when cold thermal expansion rates could be dropping your psi.

Don't over look the CSI time switch and the ECT sensors on the front of the intake. If the ECU has a wrong temp or the CSI isn't functioning as intended it will also be a starting issue.

 

Hey guys, wanted to let you know that I got it all back together this weekend and its running great! That new manifold is awesome! Had to make some tweaks with the 2 inch air flow hose, but its working out fine. I wanted to thank you both for ALL of your awesome advice and assistance through out this project. Couldn’t have done it with out the both of you!!
On to the next project...rear bumper and bushings for pistol grip.

Thanks again!!