i agree this is all confusing......the rust issue is from running the car in the winter and stuff because my exhaust is solid no clamps all the way to the mufflers and the back was higher then the front.....everytime i would start it water comes shooting out....so i was guessing some rust was forming on the inside and being blown out yesterday from the wastegate side or something..just wanted to make sure this orange smoke doesnt mean i burning something up.........
now to the spring stuff......turbo horsepower is the 1 telling me the wastegate springs should be bigger....and i totaly agree with you saying the blowoff obviously seem to small.....the other thing i am trying to find out is maybe my vacum lines are wrong?? i cant find shit on a twin setup....but i do know i have 5# springs in waste gate and correct me if i am wrong but, i should only change the waste gate springs if im not reaching my desired PSI?
oh and all the gates and blo offs are tial......
You can hear the BOV venting during wide open throttle? Correct? So we know for sure this is your issue. At least one of them. Your boost issue would be directly related to that. If the boost is being vented off the wastegate can close to try and get as much exhaust energy to the turbine wheels. But because the BOV is opening the turbos can't over come the BOV venting.
The BOV is opening till it reaches a point where the spring & boost pressure can close the valve again. Then it builds boost till it gets to the point where the BOV can't stay shut and it opens again. Repeating the process.
A manual controller can only do so much. At some point you will need to change the spring to get more boost. If the turbos are capable at least. So lets keep this simple and not take into account the pressured put on the valve bottom is more than on the top. Now the spring is good for 5# of boost. So you have 5# of boost you can hold off. Now using the boost controller lets say you add all you can to it. Full closed wastegate. It may only reach 20# because of the pressure ratio of intake pressure versus exhaust pressure. Lets say your system is efficient and has a 1:2 ratio. So at 15psi of boost in the intake you have 30# or pressure in the exhaust pre turbos. So now 30 - 15 + 5 (for the spring) = 20psi. So no matter what the boost controller can not make more boost. And like I said that is with a good 1:2 pressure ratio and not doing the math to figure out the pressure difference between the top and bottom of the waste gate valve.
Solve the bov issue first. Once you solve that worry about the waste gate and boost not being above 20#.