You said that your AFC is modifed for full travel, but did you change the spring, or add a metered orifice to control the rate that it hits full travel? Mine has full travel, but it takes 60-70psi of boost to get it there. Fueling has to climb with the boost, or it's a laggy, smokey pig.
You were saying that it smokes a lot at highway speeds with a locked covereter. Why don't you unlock the coverter, or downshift? You can't build a 12v to run 3000-4000rpm and expect it to cruise @ 1500rpm. A stock stall converter, is actually fairly high ~2200rpm. That should work well, unless you lock it up too soon. I rarely lock mine on the street. Cruising @ 65mph in OD with an unlocked converter works well for me.
The cam is not much of issue either. I've managed to get 700hp+ out of mine with the stock cam, and I can't keep it together long enough to get it tuned right. That's with that puny little 160hp pump too.