So, I've just hit my 2,500 mile mark on my 94 boosted Accord, and finally managed to have one problem.

Back pressure; so much back pressure that it blew my exhaust gasket, on the bottom two middle ports, and started cracking my metal gasket that is between the turbo and manifold.

Pulled it off today, slapped on the original metal one, and ported the exhaust side of the turbo. It's only a T25, so it's small. Has anyone ever done something like this before, to make the exhaust a little smoother flow?

I knew about a few weeks ago boost pressure was going down because it used to spike harshly up to about 8lbs. Now, after readjusting the waste gate actuator, I'm getting 5lbs very nicely throughout the power band after 3500rpms in 2nd. Probably going to turn it up just a little more, to about 7-8lbs.

Here are some pictures of what I managed to get accomplished today.

 

are you sure your flanges are not warped?

 

Nah, I had them surfaced after everything was custom fitted to the manifold I purchased.

They were warped, on both flanges, so I did send it out to a machinist and had both flanges cut. Bastards charged me like 40 bucks to cut both sides.

Both checked good after that.