River Rat, VWguy here, why are you using a 20w50 oil? The motor must be damaged or worn out! You are correct about the 10psi per 1000rpm rule, but if you are only getting 22psi at that rpm you listed you have an internal problem such as worn main/rod bearings, excessive clearances, and/or a spread center main web on the case or its cracked there. And that oil can only get so hot and thin out.
What size oil pump are you using? Stock is 21mm or 26mm. Some people will use a 30mm oil pump but almost never on a properly built engine. Race engines use these and I have used them on engines that were worn out and tried to restore oil pressure when warm.
The Magnesium case does not expand and open up as you have stated. If it does, there is a problem.
I have a daily driver '74 bug with a case that probably has the same issues you have as the previous owner overheated it and did not repair it. I have installed the Bugpack oil filter return in the bore of the relief piston and spring. I run Chevron 20w-50 oil and when it has hit a low of 35-40 degrees here in LA, my Purolator L39001 has hung in there even though my vdo o.p. guage is pegged for at least 10 mins off idle.
Went to Peb Boys a bit ago to check out the AC Delco PF13 filter you are useing. It sure is a tiny filter! And at $6 I think you could do better. My daily driver bus is a 1600, with a 1 1/2 qt sump, a Purolator L39001 full flow filter and a Baldwin B164 by-pass oil filter for a total cappacity of 7 quarts. I have not had a single problem with this setup.
I am wondering, the filter you are useing is designed for the late type 4 bus which has the relief in the mount such as the GM's do. Us VW people use the Ford style of filter, such as the Fram PH8A filter which has its bypass within the filter. Am I correct?
Hope this helps, Bill