Ive thought of checking the intercooler and I will when I get some extra time because I want to clean it out anyways.
As for the WG opening pressure, I cant set that, the Van turbo doesnt have a WG

 

I guess I missed that part, I see a regular hit of 25psi on my 80e tune highway cruise is 3 to 5 psi on my dd tune I can hit over 35 that's with the 38 sleeve bearing waste gate eliminated, I just don't think your getting full boost, could be a IC tank blowout I have seen that before but it's pretty obvious by the oil mess it leaves along the edge of the tank seam, but it does make it impossible to build boost over a certain psi as the seal fails and compressor can't keep up, its worth a look!
Jim...& fat Monty

 

I should have some time this weekend to look at the IC the boots all looked like they were in alright shape when I pulled them off to put the van turbo on. I haven't taken the intercooler out but I assume I just take the cover off the top and it slides out or is it bolted to anything?

 

It pulls straight up and out with a little wiggle
Jim & fat Momty

 

i have the van turbo set up also(as we discussed) i had a few boost leaks after installing the turbo..one at the map line where it goes to the spider and one boot. fixed those and got 25 the other day...just fixed collector and hopefully ill get more...in 80e also. i have my gauge directly into the AIH delete plug though. not sure if that makes a difference. maybe check the fitting for the boost gauge. seems way to low to take the truck sideways too...just me .02$

 

I found the problem!! The brand new boost tube I put on the truck had a slice in it. Im not sure how it got there but I took care of it and I hit 27 psi boost today in my 80e thanks for all the help