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I have a 1999 F250 7.3 w/ 6 speed manual.
I just installed brand new 160cc stage 1 injectors with PHP 6-pos.
In my 140hp tune I only see a max of 22-23 psi @ 1150-1200 degrees.
Waste-gate is unplugged and boost fooler is in place.
I black smoke pretty thick in all my tunes.
Any suggestions? As for up-pipe leaks, I don't see any black suit on the firewall.
Exhaust leak will diminish the boost. Wastegate spring can bleed boost well before 25 PSI, you might try looking into "7 turns" for the wastegate. I have a stock turbo (I think it was serviced or replaced 70K ago) and injectors with 260K. You can see my boost in the first link in my signature. Remember... I have AE and I have made absolutely certain that everything on the truck is 100% (including a T500 and fresh filter in my AIS). I had air in my fuel and I didn't trip the CEL in 60e until I fixed that.
The stock tune on my truck gets me to 22 PSI before the defueling in the program flattens it out.
Nah... I can see 27+ with my stage 1 160cc's, dp 120 tune, and I have a wicked wheel. He should be doing better than 22.
I agree he should see 3-5 more lbs without too much trouble with addition of more fuel. I know my truck without sticks doesn't get up to the 25 psi danger zone very easily.