sailorbob

Are the VSS holes omitted only from the LHS carrier?

That's waaaay too lean; burnt exhaust valves comes to mind. I once had the FPR fail on my MR2, it took a long time for the turbo to stop glowing bright red.

I'm not advocating leaving it de-catted, just not damaging a new one before finding the reason for the fuelling being so far off.

I would not put a new catalytic convertor and lambda sensor on until the emissions results are close to reasonable for a non-cat vehicle. Remove the chip and see the effect of that first. The number plate light is still available but silly money at almost £50. https://www.flyingspares.com/rear-number-plate-lamp-ud72016.html

The A132J0001S pads are marked PF6600X55XX-DS25HP if that helps. The pad material is slightly different to the DS2500 compound.

Ian, the ribs of both the lower and upper lugs are thinner than the OE casting and are not tapered so they do not thicken closer to the body. Without some high mileage road testing or finite element analysis of the stresses to see if these thinner ribs are equal or stronger than the OE casting I personally would not want to risk using them on my vehicle.

As Mike has kindly offered to coordinate any comments it is probably best to let him disclose them in this thread (if he wants to).

Yes, when comparing the CAD file to a hub carrier there are unfortunately some concerning discrepancies. Rather than clutter this thread with items spotted is there an alternative way to compile and coordinate this?

Thanks for posting the files. One item stands out, the tap drill size for the bearing mounting M7 x 1.0 mm thread is shown as 6.1 mm but for aluminium the general rule is to subtract the pitch from the diameter of the thread, i.e. it should be a 6.0 mm hole.

Will the uprights be 6061-T6? If they are just the annealed 6061 grade then they may be quite a bit less strong than the OE uprights if they are cast in something like LM25TF alloy.

This is what the inside of one of the runners looks like on the first batch made:

You are giving conflicting information about the problem; in your first post you said there was no fuel but now you are saying there is fuel but there is insufficient fuel delivery and this is causing a lean condition. It is almost unheard of for an injector driver to partially fail so, if it were me, I would check the fuel pressure next.

Have you checked the injectors are getting voltage?

Not when you are comparing the value to that in Espritmon.

The wastegate solenoid is not used just for overboost, see this thread Freescan incorrectly reports the MAP value too high.