After seeing 28.5 lbs boost (and still climbing at 3/4 throttle) with 1.4deg KR , I decided to port the WG hole mself. I started to remove the DP flange bolts under the hood & found one of the allen heads had been stripped. After removing it with a pair of vice grips, I found the threads in the ex housing were stripped, too.
Then I went under the car to loosen the band clamp connecting the DP to the rest of the exhaust, and saw tranny fluid on the the pan. I called Husek to ask him what to look for next & he advised me to re-torque the pan bolts. I went all the way around the pan, snugging the bolts & when I got to 1 of the 2 bolts holding a bracket to the trans on the driver's side, I found one that wouldn't tighten. The threads in the case were already stripped!
I proceeded to remove the DP & port the WG hole. And, it looks like I screwed that up all on my own. After completing the port job, I bolted the DP back up, and the car would quickly jump up to 15lbs of boost & then slowly climb to around 20 (@ WOT). I adjusted the actuator rod tighter a few times, but with little to no improvement.
Next, I decided to swap the the re-countered Garrett ex. housing Bison just sent me (which now has a stripped out bolt hole & over-ported WG), with the Precision unit that was included with the new turbo. I removed all the plumbing & then the turbo from the car. I was up till 3 a.m. in the driveway using handtools (my kid was sleeping inside or I would have used the compressor). It reminded me why I paid a so-called professional mechanic to work on the car in the first place.
I got the turbo put back together & back in the car & called it a night. This morning I got up, went back out, & finished the job. Everything went reasonably well, but it still took me 1/2 the day.
Now I've got the car boosting to 25 lbs consistently and "0" KR with the Alky on 7. It's not as snappy as it was initially, but at least I can put it to the floor again.