So I finished my engine swap about a month ago (25 neo in a 32) and sent it off to boostworx to get a few minor things fixed up new metal intake, getting some broken studs and stuff I cbfd doing myself fixed.
Now everything was finished up last week and the car seemed great the first 5 minutes then I noticed that on 18psi when the turbo spools up whether you flatten it from 2k or rev it out slowly and then plant it at 5k it makes this flapping trumpet noise as it spools to full boost, the noise goes away after full boost has been achieved though. So if you drive it flat from 2k it happens around 3-4k then goes away, or if you rev it to say 5k and plant it it happens around 5.5-6k then goes away.
I thought possibly at peak torque the engine was cocking over and slightly causing a gasket or intercooler pipe to leak however we have pressure tested the entire system and have not found the leak, it also doesn't really happen on the dyno only on the road so we can't find it when sticking our heads in the engine bay.
The noise is an extremely loud trumpet flappy noise, being as it only happens on the road it is proving very difficult to diagnose. Apart from pulling the intake manifold off and redoing the intake gasket (I had to swap it during my coversion) I'm not sure where else to look, rather not do this as its a huge pain in the ass and might not be the issue.
Aside from replacing the clamps on the silicon intercooler joiners what other gaskets etc should I be looking at? We have already had the AAC gasket replaced and replaced the studs for the TB as they were leaking as well. Sounds like it is coming from the bottom right of the car when driving, but that could just be because of where the driver window is. AFRs are fine and the car doesn't run rich so there is a possibility it isn't a leak and something entirely different.
Any ideas be much appreciated.