Actually, if the stock fuel pump is in there you can have problems with even a full tank. When I recently pulled my old stocker out you should have seen the strainer sock. It looked like a piece of beef jerky. No kidding! After replacing the pump, the difference was tremendous. Yours could be clogged and is probably collapsed as well leading to fuel starvation. That coupled with low voltage to the pump will undoubtedly give you problems.
The gauge in the dash isn't going to change the fuel delivery of the car. My gauge is pretty screwy too. I don't think the float is the problem on the sending unit unless it is binding up for some reason. You can check this when you pull it all out. Usually, it is bad/corroded connections on the sending unit. There is a guy on here that created an entire page on how to fix a sending unit. I suggest post a message in the "Fuel" area on the forums and see if someone has the link. A new sending unit is impossible to find and if you do find one it is going to cost you. If you need further info, contact someone at
www.casperselectronics.com. They have everything electrically related to our cars and they specialize in digital dash stuff. I'm not sure about the wiring.
Oh yeah, most people (including myself) will tell you it is a good idea to get into the habit of NOT running the tank that low to begin with. I never go lower than 1/4 tank. There is a slight chance of the pump being starved of fuel during heavy acceleration due to fuel being pulled to the rear of the tank.
A very common upgrade is what is referred to as the 009's. These are rated at 42-43#. However, recently a lot of people go to the 60# Motoron injectors which are pretty big and allow for a lot of "growing room." Plus I hear they are very tuner friendly and do not require an ECM upgrade. I personally have 009's and they work fine for me. The stock injectors are rated at 28# and stock replacement injectors are 30#. You will need to have a new chip for anything above 30# injectors for the car to run correctly.
Your best bet is to try
www.racetronix.com for injectors. You'll find the best deals on injectors there, especially the 009's.
I did the same thing that you did by blowing an intercooler hose off one time too. I about **** my pants and thought my engine was gone.
I know it sucks money wise, but you need to have that adjustable regulator soon. It's a necessity. I really think with new injectors, pump + hotwire, adjustable regulator you'll find a world of a difference. Plus all of those things can be done in one day provided you have someone help you raise and lower the fuel tank.