having that piece fall into the turbine at 100,000 rpm is a much bigger worry.

 

I'd pull the turbine housing and inspect the wheel.

 

I'm curious of why you're re not boosting more than 27lbs of boost?

 

I can't boost 27 or more pounds, the problem I believe was that damn gasket that had had cracks and was leaking like crazy.

 

I had something similar with that on my stock turbo. It wouldn't let me boost past 23lbs we checked everything and boost leak tested it and it turned out the be the wastegate actuator. I had to preload it more. I turned it in 2 times and it actually boosted less and then I went in another 2 turns and now boost is back. Just a thought, maybe worth checking out since you've tried everything else. We also thought it might of been a gasket or exhaust leak but to rip everything apart to find out it's not it is very frustrating. I'd try preloading before I rip it all apart. Good luck!

 

I was also told it could be a bad turbo or engine going bad because we looked at everything, even going back to the stock bov and I boost leaked tested up to 28lbs no leaks. We couldn't figure it out but it was easier to try the preload then to swap turbos. And it was just the wastegate actuator.

 

Look into a bigger turbo at this point. Green red black pick one. A green with e85 your looking at 500 pounds or torque with decent top end.

 

So I regret to say I retuned after I replaced the manifold to turbo gasket and manifold to head gasket and gained no power but I did gain 1 psi extra. I am at 354AWHP at 28 psi. Tuner believes turbo is probably bad because since a piece of gasket was missing he thinks it hit the hot side turbine. The thing is that there is no shaft play whatsoever and the turbo is as smooth as silk. I am getting spikes of 31 psi on 4th gear then it drops to 28psi. What I suspect is the throttle body gasket leaking but I don't think it's 50+WHP worth of leak.

 

What intercooler and what intercooler piping? What Tomei cams specifically?

 

I don't know what brand my intercooler is but it's define toy aftermarket, I have Ets pipes and I believe my cams are 280. I have no boost leaks.

 

its not the turbo, so stop looking there. has cam gear timing been checked? how is the boost test being done? like where are you pressurizing from? and what is your source of pressure? what are you blocking off for test? if anything. is blow off valve open to atmosphere? or recycled? how bout the exhaust? how many mufflers? or any of them old and possibly collapsed on the inside?

 

Boost leak test was done pressuring the intake side of the turbo and we heard at 10psi very small leak on the throttle body seal but tuner said all Evos do that. Cam timing Is perfect. Blow of valve is a aps dual stage recirculating , exhaust is a Megan exhaust with straight piping and a Tomei 02 housing. I probably suspect the Throttle body seal and the BOV, they don't make that BOV anymore so it's probably old, came with the car when I bought it.

 

I don't know where the boost gauge reads the boost from but on highway at 70mph when I floor it i boost 31psi then tapers down to 27-28 psi. I don't think the engine is taking in that much.

 

throttle body leak is not the issue. and that leak can be fixed by tightening the nut just a little.
I would try another BOV before doing anything else.

 

Have you or AWD verified that the reluctor on the exhaust cam is installed correctly?