Boost saga continues... (longish)
 

I recently cleaned my MAF connections and thought the car was driving a little better. The next day I still noticed some hesitation type behavior but more so than the day before. Then 11-12 psi only. Today I took off hoses, cleaned, checked for rips/tears etc. and nothing found. Tightened all clamps again. test drive. 23psi on one pull, then 13ish, then 15ish, then 11ish. Cant seem to hit 20psi again. What could cause this type of behavior? I also just changed plugs and boots so that isn't an issue. The intake hose (MAF to turbo) is looking kind bad at the turbo connection and I have another one in route. Could that cause this type of problem? I have been getting overboost code but haven't seen the engine light flash on at all this week since cleaning the MAF connection but the car was still cutting out under load/high boost. WGFV pops in my head but I don't know if I can test that in anyway.

What about the intercooler? It would be possible that it got hit by a big rock or one of...
 

the plastic end tanks is cracked. May not be likely, but looks like you've done your due-diligence otherwise.

Good luck Jason... if there's anything I can do to help, just let me know.

The IC has metal end tanks.

I would do a boost leak test first,and eliminate any cracks or leaks,,,
 

before I bought my car the PO had it in three different shops and they couldn't find the leak,after I bought it I put my testing equipment on it and found the leak.

I did, see the image for an explanation
 

<center><img src="http://pictureposter.audiworld.com/137143/compression_test.jpg"></center><p>

I've seen these leak

The way you did that, there is a pathway, through the turbo (seals), through the EM, through the
 

engine, through the Intake manifold, to the ISV (on the backside of the throttle body). Seems strange considering there is also an easier pathway throught the downpipe.

Suggest that you test from the turbo outlet hose (cap it there), pressurizing from the throttle body end (still with the ISV branch and cam cover vent hoses capped). That should isolate everything between the turbo and the throttle body.

2nd that,I made up a kit with regulator to plug onto the intake side of the turbo.