Originally Posted by DDD

Do you have a decent aftermarket boost gauge where the clock normally goes in the dash? Reason I ask is that you have no reason to fear overboost unless you actually are experiencing overboost. None whatsoever...either your wastegate is dumping at 1 bar or it is overboosting, but not both, if you know what I mean. When you actually let off the gas pedal you may see a quick spike when you are off throttle before the recirculating valve cuts in to channel the air back into the turbo, but that is not the same as overboosting your target of 1 bar while on the throttle. In fourth gear, with your foot to the floor, it should hold steady at 1 bar, but when you let off the gas it might spike up for half a second before recirculating, but that is not overboost. That is normal.

Overboost is a problem in only some cases with a Tial wastegate, not normally the factory wastegate, and not always with the Tial either.

As far as intercoolers, blown6 has supposedly cleaned up their product, which started out a little bit rough to fit, but they have supposedly stepped up and address their issues. Even a half bay IC from them would totally set you straight for your needs.

For less than a grand you can get a goingsuperfast IC, which is actually made by extreme intercoolers for GSF, and so it is a very good unit. The only problem there is that it will not be completely bolt on, you will need to probably line up the entry and exit tubes yourself, but that is the cheap way to go if you don't mind monkeying with it.

When going to a better IC, you should update to a modern C2 type diverter valve and dump your old fashion recirculating assembly. Imagine Auto can actually hook you up with parts for that. They also sell B+B intercoolers where you would not need to make the conversion (short neck style). Don't know about the cost on those, but they are good ICs as well.

Lots of ways to skin a goose.