So I've just been out for some more data logging to try and work out what is going on here, and I really think it has to be a boost leak somewhere, but I have no idea where/how to go about tracking it down.
Idle fuel adjustment when warm sits/jumps between 105% and 110%, however after some pulls (first couple of pulls performance is fine, then dies off to crap again) the adjustment jumps and pegs out at 125% at idle... So I'm guessing extra un-metered air is getting in somehow?
So I'm thinking, somehow something is "opening up" after pulls when the car is hot, then closing itself when it cools down and I stay off the boost.... But what!?
This would make sense why the pressure testing of the intake showed no leaks..
Anyone got any theories on what could cause something like this?