Couple of thoughts here. If he ran the tank dry, and that fuel filter is already a few years old, it wouldn't hurt to replace the filter. Whatever crud that was at the bottom of the tank is likely in the filter now, clogging it up.
Another possibility to consider is that when you guys did the work to change out the fuel sender, it's possible the fuel pump wiring may have been bumped, damaged or distrurbed enough to result in the intermittent hard starts. 20+ year old wiring is likely pretty brittle & corroded as-is, so you might want to take a look at the integrity of the wiring & connectors and check our the fuel pump circuit per the FSM.
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