well i've got about 2500mi on it since the rebuild. there were some more blunders, trials and tribulations, quirks and kinks and more yet to still work out, but relatively minor. drives great!
11mm alh pump + lift pump, .260 nozzles, 1856 turbo, ported head + stock cam
in the meantime i got back into experimenting with maps and have made the following progress:
-4bar map working correctly - still want to test it in a more controlled way than looking at boost gauges + logs to make sure it's completely accurate
-fuel limits extended to 102 (makes sense given i'm using .260 nozles - double the hole surface area as stock?)
-tweaked coolant glow plug operation
-changed all idle speeds (or at least i believe, may have missed a couple oddball ones)
-boost, fuel and SOI maps adjusted for good power to 32psi - these need much work! especially n75
-limiters made more conservative to protect drivetrain, engine and turbo
so far, it generally runs quite well, except my boost control is totally off, but is completely drivable, just need to be somewhat careful. when i get on it with a lot of fuel, it really rips, and EGTs don't seem to be anything dangerous. in order to get to 1500F i'd probably be at speeds i'd lose my license over
in steady-state driving, i believe they are lower than what they used to be. cruising at 85mph ranges from 700-950F on slight inclines. my guess is it seems to be close to 775-800 on flat road and no wind. i believe if i got my tuning better, i should see less.
i posted on ecuconnections but will also post here, some issues, questions:
- it doesn't seem like my limiters (torque, IQ by Map, boost) are actually limiting anything. for example, i tried to limit IQ to a max of 50, yet went for a test drive and hammered it and went well beyond 50. i can also mash the go-pedal at low rpm and it will easily boost much higher than what i've set in the limiters. i'm wondering if there are some switches that are set making these maps ignored? although since the file i'm working off was initially from vwmikel, i would have thought they would be active. but maybe i'm barking up the wrong tree and misunderstanding something.
-i've tried a few strategies to get a good pump voltage map. take my current one for .764s and scale it up. runs decent. tons of power when i scale it up more to achieve max pump voltage at 3500rpm when max boost is available. idles decent, but i believe it should be smoother. i'm trying to get a really nice smooth idle at 818.
- another thing i've been trying is take what i believe to be a stock map for 11mm + .184 nozzles (the mk4 automatic) and work from there. since hole surface area is almost exactly double (0.00016486 vs 0.0003292), should simply be able to scale the map up to 102, and expect relatively correct actual injection quantities? or perhaps slightly less due to pumping losses or some other factors i'm unaware of? i'm not expecting perfection, but sane values would be nice.
-lastly, and i still have trouble with this.... is how to get my QA into a sane/realistic position for IQ values to be sane. i'm sure this is part of my problem in getting a really nice clean idle. if i put in a stock 11mm pump + .184 nozzle map, would it make sense that the QA to be in factory position, i should see about 2 or 2.5? if 5mg is a real world value for 903 idle, and i put injectors with double the hole size, it would under-report? or do i have things backwards and mixing things up again in my understanding of the QA position. even though i've read kerma, dbw and others descriptions of it a million times :| in some of my futzing with pump voltage maps, it ideals OK, not nearly as smooth as i think it should, at 881, even 818. reads 5mg, but i start slowly pressing the accelerator and intially see IQ drop to about 3, then start rising again the more i press. so something there obviously isn't right.
-having a bunch of trouble dialing in my n75 and boost maps to be a safe 32psi. i think i could make this an easier process if my torque limiter was limiting fuel so i could limit it to say, 20mg, 40,mg 60mg and take some logs under WOT. right now, i overboost too quickly to be able to safely do this get any good values
phew....! more later i'm sure...
SIGH. very depressed right now 
. Very little smoke anytime. Now I feel like pid control could be tweaked a little to optimize it more. So far I've only worked with limiting the upper (or lower whatever it is) n75 limits to make sure it doesn't try and snap vanes shut too much.
no issue with egt or too much smoke. Definitely a bit of a haze when I really get up there but not much.