Ok I may be missing something here so don't laugh

I've noticed at least a few times when I do a boost leak test it builds no pressure and the air is coming out of the DV (where it would connect to the intake pipe)

If I disassemble/resassemble the DV it doesn't leak. It's nice and lubed up.. I can't think of anything I'm doing differently when shutting the car off. The engine is fairly cool. I'm careful that the spring seats in the upper portion of the DV.

Forge DV (newer style w/o adjustment) blue spring 1 "spacer". Spacer is in the bottom side of the DV. Pretty basic eh

 

Add some washers into the chamber under the spring to see if that helps keep it sealed better.

 

Still did it with 2 spacers.. I'm now trying out the yellow spring.. seems to be better as far as drivability... I also cleaned/relubed everything... so we'll see next leak test I do.