Pressurized my intake, blew the breather off, is this right??

Kev, maybe you already posted but do you have any codes?

Vacuum is lower during a cold start until the walls and rings get oiled and the piston/rings/walls start to warm up and seal.

I agree, it sounds like something may not be sealing, but I don't know what is going to get warm enough in 30 seconds to make a difference.

Also, have you checked fuel pressure?

Pete, I haven't had any codes since I changed the TFI out around a month ago. I realize that vacuum is lower at startup, but my vacuum hovers around 10-12 inches when I first start it up, then it's at around 19 less than a minute later.

Checked fuel pressure and had about 45 psi on the stock regulator with the vacuum line unhooked. I thought that was weird and I bought an adj. kirban to replace it. I set the fuel at 41 after testing different pressures trying to get rid of detonation. The detonation never went away--assume boost leak or vacuum leak--so I had to reduce my timing to 10 instead of 12. I still get a slight detonation at WOT at the top of 3rd gear, but it's better than it was. I'm hoping that when I find the vacuum culprit, it will sort out the dieing/1st and 2nd gear hiccup/detonation problem. Yeah...hoping.

Ok. Cold vacuum of 10-12" is low
How about air leaks, not vacuum leaks. Anything between the VAM and the front of the TB.
VAM hose, IC hoses, leak in the IC itself??

Air leaks is what the pressure test should find. I could put my pressure tester on the front of the VAM instead of the turbo, but the VAM doesn't see boost and I was afraid the 20psi would pop its top. I'm not sure how to test for leaks around the VAM.
As for the intercooler, I didn't hear any leaks in the couplings around it or in the intercooler itself when I pressurized it yesterday. But, I was pressurizing the valve cover too and air was coming out of the oil cap and breather, so I wasn't able to get the full 20psi in the engine before having to shut down the compressor. I'll know more in a couple days after I get the gasket replaced, and I'll report back then.

Kev, I meant the VAM hose, take it off look for worn spots, especially the bottom area where it might be rubbing on something

Unlikely it's the VAM hose since it's all of 3 inches long, but I'll check it anyway.

poor idle on cold is usually a condition of a faulty or mis-adjusted TPS. check that its set at .94v KOEO. (off)

-J0N

also, there was a tsb in the late 80's with cold start up issues caused by excessive carbon on the intake valves.. however the fix would be to take it to a ford dealer... and find a tech that knows how to use the appropriate tool.. good luck with that. however, im not sure if the tsb really applies, seeing as it was a problem with fuel that people were burning

Is the EGR sticking open a little bit?