Help plz only 5 psi max boost

[skyzim]

So i can't figure out why i can only get to about 5 pounds of pressure from my turbo.

Setup:
KA24DE-T
Weisco Pistons 89.5mm
Megasquirt I PCB 3.0 Full Standalone
460cc Rx-7 Injectors
Hitachi HT18-2S Turbo
Unknown log type Turbo Manifold
Tial external wastegate
HKS SSQV BOV
Unknown intercooler
Custom Piping

Here is what I have tried and what kinda symptoms I am getting.
1) I have done a boost leak test.
boost leak test seems to be good, I do although hear air coming from my oil fill cap (Not sure if this is normal cause of pcv or not)
2) I have a custom exhaust with a hi-flow cat so I should not have excess backpressure from exhaust
3)I have tested boost with the wastegate and bov both pluged
This yielded no results and from what I understand if a bad wastegate is pluged you should continue to build boost.
4)I have rebuilt the turbo itself, installing new bearings and seals.
what i have not done with turbo is balance, and the compressor wheel fins are damaged some (a few chips)
The turbo spins freely and spins at idle, I can however stop it with my fingers by squeezing the compressor bolt. (Should it be harder to stop it spinning?)
5) Turbo spools the best in the morning when the engine is cold. Thats when i get the best pressure and spool time. Once it warms up though it takes longer to spool and pressure seems to drop.
6) Side note my car is not perfectly tuned, but it runs fine. I understand if timing is too retarded you wont build boost, but I have it set to stock timing and retarded about 1 degree per psi. (I believe this is fine)

Ok, thats whats going on so far. Any input is appreciated. Thanks.

[nissan240boy]

ok i have a ka24det and im running 9lbs of boost and she runs great and spools very quickly and im running a $200 ebay turbo, fyi if u plug ur waste gate and u got no increase in boost either ur turbo is junk and not spinning fast enough or you have a major boost leak, also a major boost leak will make that turbo spin insanely fast to make up for the lost air till it opens the waste gate and ull ruin the turbo with a major leak over time. My turbo builds 9 lbs in about a second if I smack the throttle to the floor at 4,000 rpm, also kat's make there power between 3500 and 6000 rpm. You should never try to stop the blade of a turbo while its spinning one so you dont loose a finger and two so you dont cause the nut to come loose on the compressor wheel, when you accelerate and slightly get on the gas, can you hear your turbo spooling or do you have to really get on the gas to build boost and to spool the turbo, check your turbo exhaust gaskets, if the gasket between the manifold and turbo or thr downpipe and turbo has a leak youll have major boost lag, your exhaust must be sealed 100 percent to the downpipe, also im pretty sure on this and guys feel free to tell me if i am but you set your timing to stock, you dont advance or retard it, thats what the ecu is for it will adjust the timing acordingly if the ecu is tuned correctly for the setup cause having the timing too far advanced or retarded will destroy a turboed engine, hope I helped you some

[skyzim]

Yeah I kind of think my turbo might be on its last leg but you would think it would work properly since I put new bearings and seals in it. Also it's only at idle that i attempted to stop it spinning with my fingers. It spins fine at idle it seems but wasn't sure if u should be able to stop it spinning like that. I've check for turbo manifold leaks multiple times and made sure the gaskets sealed properly. Oh and it only takes light throttle response to get the turbo to start building boost. It just will only get to around 4-5 psi when I floor it.

[biggie]

Where are you measuring the boost? What is being used to open the wastegate, any boost controller or just WG spring?

[skyzim]

I am measuring boost Off a vacuum line from the intake manifold. I have a generic boost gauge and also megasquirt map sensor. They both read correct and when I preform a boost leak test both gauges read the correct pressure. The wastegate is opened by the spring which is 14.7 for the tial wastegate. Although as I stated b4 I tired running the car with the wastegate line pluged to make the turbo continue to build boost, which yielded no results.

[biggie]

Hmm, I was thinking if it was the original WG spring it would be 7psi and 5psi at the intake mani would be normal.

[compactfean]

You shouldnt be hearing much air coming from the oil cap. Plug off your pcv hose and do a boost leak and see if it gets better (there will always be some sort of air coming from the crank case.) As for the lack of boost it could be a few things. boost leak, exhaust leak, weak spring in wastegate, bad valve or valve seat in wastegate (you can hand lap the valve if that is the problem) bov not sealing right (usually you'd find this problem during boost leak test) id say with what you've Already told us, id say its an issue on the exhaust side..... wastegate valve seat or exhaust leak (it would have to be pretty noticeable)

[skyzim]

I've checked and double checked for leaks on both exhaust and compressor side. The only thing I can think of at this point is the compressor wheel chipped and its probably out of balance.

[blkvrtswp]

During your boost leak testing, what are you seeing on the boost gauge? If you can't get it over 5 psi with the compressor & TB blocked off you probably have a boost leak. Those bastards are real hard to track down and eliminate sometimes.