Looking at Snow's instructions it looks like they just want you to drill and tap the intercooler pipe to install the nozzles. Is this what you did? My questions are:

I have bungs, should I weld them on and use them for the nozzles? My fear raising the nozzle into the bung might disrupt that the spray pattern.

Is there enough metal on the stock pipe alone? I'm making 43 psi. Don't want to have any projectiles under the hood.

Last they recommend for 425-450 HP the one 625ml/min nozzle and one 375ml/min nozzle. 550-650HP use two 625ml/min nozzles.
I'm 485 before the injection so I should wind up around 530-540.
Any suggestions on which nozzles to run?

 

Sounds like you should screw them in. Then buy both sets to see which one's you like. Your running that HP with WVO? that's great. How loud is the G2WW? That's really good on the stock turbo as well.

 

Are you really on the stock turbo? Also, do you plan to spray water only, windshield washer fluid, Snow's Boost Juice, or will you be mixing your own stuff? I've run all of those setups. With washer fluid or water, I could stand to go up a nozzle size. With boost juice my nozzles are about right. With my own mixture, I have to wait to begin injection until after 20psi or so. If I inject my mixture at lower boost pressures, the engine will start missing out. If I wait until higher boost, I pick up almost 20hp over boost juice.

 

Yupper! Wheel is not loud at all.

Stock housing, 1.0 exhaust housing.
I was going to just spray washer fluid but never thought about mixing my own batch up. Willing to PM me a recipe? I was think start at 15 psi full on at 30 psi.

 

So the turbo that you're running isn't a 66mm drop in of any kind? Just a stocker with a billet wheel? If that is the case, I would run the both smaller nozzles to start with. See how it feels and maybe bump one up to the larger nozzle. I doubt you'll need both larger nozzles. I'm using one 625 and one 375 nozzle in my truck and I am fairly certain you aren't making the power that I am with that stock turbo.

I don't mind posting what I do publicly. In my truck, I'm mixing 55% VP Racing M1 methanol to 45% distilled water. I have a gallon water jug that I've marked at different spots for 45%-55% of a gallon. I initially used a measuring cup and water to make the marks on the gallon jugs. If you want to mix your own juice, just get some methanol and distilled water. I would recommend trying a small batch at 45% methanol and another at 50/50 just to see how you like it. If you want to step it up to 55% go ahead, but fair warning, this is a potent mix. EGTs will go up quite a bit and the risk of hurting something is higher. I've been running my 55% mixture for 2 years without issues, but that doesn't mean the same will happen to you.

 

So what turbo and injectors are you running Travis? Have you had yours dyno'd also? I guess you both are building these for racing more then towing? I would think water only while towing.

 

I've been running 160/100s with an S465 charger. Fixing to update to 238/100s and a different compressor wheel. I've done plenty of dyno runs, track runs, towing, daily driving, you name it with my setup. I've done dyno tests with several different mixtures from fuel only, straight water, up to my 55% methanol mixture.

I can tell you that my WOT EGT readings with my 55% mixture is 400*+ hotter than fuel only EGTs and smoke levels are a pretty steady haze under WOT. You'll notice that with more methanol, there will be a little more black smoke. When I'm towing I run either straight distilled water or washer fluid. Daily driving I run the good stuff.