some times with a really free flowing exhaust you can end up having probs like this (look at an xr6t) ther seems to be a point where the wastgates just cant get rid of enough gasses and your boost will start to climb no matter what you do. if your flap opens to full extension without jambing then i would look at removing the turbo and diegrindig the wastegate holes.
make sure when you do it leave enough meat there for the flap to seal on 2mm is enough.
give that a go if you have exhausted the other solutions and still cant fix it.
put a backpressure gauge in the dump pipe and if you have less than 4psi i would almost put money on this being the prob.
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