My New Turbo Problems.. Options

[Rollout]

I've kept it kind of on the low up until now, but I recently (finished totally today) installed a super16g on my car, w/ tubular manifold.. Check out my garage for pics and what not on that:
http://www.dsmcentral.com/invision/index.p...&CODE=12&CID=17

But... ever since the install I've had hella problems...

#1, the manifold (I believe it was a prototype KOU manifold) isn't aligned perfectly, so everything is crooked, all the oil lines had to be fabricated, and new fans had to be perchased.. Luckily all these problems appear to be fixed with some serious help from Carl Crawford (Owner of Speed-Source). Can't express how helpful he was with the installation and letting me use his shop + lift to do it.

#2, this manifold gives off some serious heat.. On top of that, it puts the flange where the manifold mats to the turbo about 3 cm from one of my new fans.. I'm afraid it's going to melt, I've already smelled burning plastic when stepping out of the car, and that hasnt even been during serious driving... The only ways I can think to fix this problem are:
a. Thermal wrap, but I'm afraid the manifold will crack...
b. Heat sheild (at least in front of part of the fan), this seems like the best solution, but there really isnt much room to work with there... and two it will block some airflow..
c. Put the factory manifold back on, but this would mean im stuck with a tubular manifold and O2 housing, and plus i would need to purchase a HRC O2 housing..

#3, I'm having boost problems... I'm thinking it is because I am still running the stock downpipe and just having serious boost creep.. I have the AVCR set at .65 bar.. I would assume that is somewhere near 10psi or less.. Actually, I'm not even sure this wastegate will allow for any less then that, but none-the-less, the turbo should not be seeing levels of 16 psi when its set that low... Tomorrow I'm going to bypass the controller, and just route a line from the wastegate to the turbo for now, just to see what the minimum boost is, and to keep things under control until i can get this thing properly tuned.

#4, I cant tune this thing, i dont have a datalogger or cable..

Other then that, seems to run good, I'm just freaking out

[natedogg]

The HRC super 16g's have 10 psi actuators.

As far as boost creep goes, it can happen either way. It all depends on the wastegate. Intuitively, one would expect a larger downpipe to allow more boost creep because of a larger pressure differential and this does happen. The problem that the small stock downpipe presents is the smaller pressure differential created by it applies just as much to the wastegate as to the turbine outlet. And the exhaust gasses would rather travel through the turbine outlet than the wastegate outlet because it is the path of least resistance, since the pressure on the turbine inlet is increased indirectly with the increased flow from the 16g compressor. A few Evo owners have run into this problem by slapping a larger turbo on the stock downpipe.

Like Spy alluded to, it all comes down to matching. Port matching the exman to the head, the turbine housing to the exman, the O2 housing to the turbine housing, and the downpipe to the O2 housing. Consequently having the correct size wastegate outlet to match the turbine outlet makes a difference as well, but that isn't really flow matching, more like flow resistance matching.