Right now i have a saab t25 turbo w/ internal wastegate and acuator. I didnt have space to mount the acuator so i mounted it above the exhaust manifold and lengthened the rod about a foot and used mechanics wire to attach the flapper to the acuator. Is it bad to pull on the acuator to fit it on the flapper, or should there be no tention on the spring to keep it closed? 1st and 2nd gear is like 8psi then 3rd 4th and 5th fall off to 4psi. I use a mbc to raise the boost the boost to 8psi, without the mbc it runs 5psi. Should i take the tention off the spring and then use the mbc to make it boost higher instead of a shorter wastegate rod?

 

Would also like to know the answer to this... anybody?

 

Probably spiking. The taller gears draw out the rpms and don't show spiking.

 

It's fine to have tension on the rod.
I once had a leaky wastegate that was solved with jbweld on the seam around the body.