Boost Control not Controlling Boost

I finaly got around to replacing the broken BCS. It was all cracked and didn't seal correctly (must have been a large vac/boost leak).
When I had the stock BCS in the car would boost up to about 16 PSI independent of the fuel switch. I did notice a chattering sound when I let off the gas after reving the engine or coming off boost quickly.

I installed a manual boost control setup. For now it is functioning as a standard Gilis valve. I set everything for basically 0 psi(bolt all the way out), double and triple checked the plumbing and went for a drive.
I was expecting 10 ish psi (what I've heard the WG spring is rated for) but instead got about 18. I'm not sure if it would have gone higher but I didn't want to push it. When I let off the gas there was a brief whooshing air sound similar to a blow off which I can only imagine is boost leaking around a coupler. The chattering sound is still there.

The plan for tonight is to hook up a small compressor and see if I can get the WG to move. I may also throw the compressor in the back seat and see if I can hold it open while I drive (should see 0 psi on the gauge).

I've also been using the notorious stock boost gauge, I'll setup something more accurate tonight too.

From what I've searched and and read on the forums the boost does seem to be coming in later than average.

Where should I be boost wise with a stock setup at various RPMS?

Any thoughts about why the WG doesn't seem to be actuating?

Anything else to check?

You may have a ruptured diaphram in the waste gate actuator. Grab ahold of the lever arm that is on the end of the shaft coming out of the turbine housing and see if the shaft will turn. I have seen plenty of rusted stuck waste gate shafts. If it moves freely, do like you said and use your compressor to apply 10-15 psi to the waste gate line and see if it moves the actuator rod.

When I let off the gas there was a brief whooshing air sound similar to a blow off which I can only imagine is boost leaking around a coupler.

If something is leaking, it should leak before you lift off the gas, not after. The whooshing of air is the pressure wave bouncing off the closed throttle plate and reversing direction and heading back toward the compressor wheel.

On the drive home, no change. As soon as it cools off some (car and weather) i'll be out checking as hawk mentioned.

Pete, I know what you mean about that surge. I'd never had it happen before which is why I thought something might be leaking. I have to double check if it happens at ~15psi or only higher pressures. It hadn't happened prior to last night.

Update:
Tried to move the rod coming from the wastegate actuator and was able to just barely move it. I hooked up the compressor and pulsed the air to the actuator. It sounded like it was moving so I started the car and repeated the test. The jingling sound (at idle) would go away when i sent pressure to the actuator leading me to believe it was working. I then hooked up the pressure gauge to the fitting I was using to get pressure and went for a drive... almost nothing. Only got some pressure when the throttle closed agressivly.
I switched the gauge to the other fitting (I'm using the two on the outlet of the compressor) and went for another drive. This time the gauge followed the gauge in the car, indicating it was seeing pressure.
I connected up the boost control valve again, dialed the bolt 99.9% out (no pressure on the spring) and went for another drive. It is still boosting to 18ish psi...

I'm going to try actuating the WG with the compressor again. How far should it move?

Tried to move the rod coming from the wastegate actuator and was able to just barely move it.

That is the way it should be, very hard to move.
Apply 10 psi to the diaphragm port and WATCH the rod.
It should just barely move toward the WG pivot arm, only a few thousandths.

With the gillis, the fitting in the compressor outlet is removed and the hole plugged. The gillis gets its signal from the vacuum tree,
http://www.turbotbird.com/techinfo/Gilli...sValve.htm

I'm hesitant to use the vac tree as the reference because as soon as you start to close the throttle, the wastegate will close even though the turbo is still making boost...

I dont mind being a little gentle on it
http://www.boostvalve.com/tech.html

I would rather put the tap on the cold side of the intercooler before the throttle but I've got bigger plans. (my motivation for doing these mods now was the stock BCS was a POS and was leaking a good bit of air)

Bill, I'm thinking that the fitting in the compressor outlet is messing things up. Just to check that, try sourcing a the tree to see if anything changes or remove the fitting and just put in a single port fitting and try that, just to test for a change in boost level

I have no idea what the jingling/chatter noise is. Is there any free play in the rod from the WGA to the WG. There should not be. The rod should actually hae some pre-load on it.