Thanks for your reply Paul33 - big fan of your PowerFC FAQ btw .
Yeah I've heard it's pretty uncommon for the actuator to fail. Only thing I can think of is the diaphragm may have a problem.
I bought the HKS GTRS brand new, genuine, standard trim, with the actuator already attached. I fitted the turbo myself and no one else has touched it. But I didn't check the actuator bolts tho. I assumed they were already tight.
I've got a cheapo one piece dump pipe + front pipe. It has a bell mouth opening and I can move the wategate flap manually without any interference. The flap can open right up so I don't think it is hitting the dump pipe or catching on it.
I will check it for play or movement on the actuator bracket tho. Thanks for that.
Anymore ideas?