Originally Posted by Jafro

If he's able to build up pressure in the intake, there shouldn't be any cracks in the manifold, but I think you're on to something.

The 14b is internally gated. I bet you've got a pretty hefty crack in the exhaust housing of the turbo. Even though you hooked the wastegate back up again, I bet it's not closing all the way, or the flapper doesn't seal on the wastegate port. That can be caused by either a crack, or the wastegate actuator.

Have you tested the actuator to make sure it works? Put your bicycle pump on it, and see if you can get the actuator to move (but don't honk on it too hard or you could bust it). It could be jammed or might have a busted diaphragm. The rod might not be bent or maybe not the right length.

It's got to be the wastegate if your BOV stays closed when the car is running, and if you've sealed up all the leaks, and you still can't build boost pressure.

I guess it's possible that your vacuum stuff is hooked up in the wrong place and that it opens when you start the car... but I don't know how that would happen. What's your boost source for the wastegate?