I hate to say it....because i am a glass half empty guy. But I feel there is a good chance you are a candidate for another blown gasket. You could be good at idle and when the boost starts to build you are feeding the cylinder with a mist of water. It wont smoke like the truely blown head gasket...white smoke generator type....but that is just my 2 cents.

 

I have a feeling you are correct; however, I just can't accept that yet! The engine hasn't seen over 12psi of boost! But the water has to be going somewhere, right? XLR8R said I now have bragging rights to largest homemade water injection system...

Take that Mr. John P.!!(AKA Mr. Water Injection) J/K...

It is frustrating though to have put on 3 gaskets and not solved problems... you know how much work goes into changing one of those things on my truck??

 

My bet is its not a headgasket, can you smell anything sweet when you run your heater in the truck?
Floor mats wet?
Might have been a headgasket 1st time, but I bet its not this time.

 

Well only one thing to do if you can't find the leak. Off with the head again...

 

If it was me with this problem, I would be pulling the T-state out, and refilling the system from the upper radiator hose, then driving it a day to see what happens then, just make sure your cooling the radiator down before your pulling the cap everytime, if its building pressure in the radiator after you cool it down, then chances are it could be a headgasket.

 

No sweet smell inside or from exhaust... and I run the heater all the time!

 

Just so happens I've decided to try that fancy "headgasket repair" stuff... and see what happens. $20 vs $1000....

 

that stuff is like using a piece of bubble gum on a waterdam leak. with the boost numbers you are capable of running, it won't last long

 

^^^^ I totally agree... but I have to drive this for now and don't have down time for it... again... to figure it out correctly. Maybe after tax return time.

 

Just to update this, turns out the rear freeze plug in the block was leaking, but would only do it about 200 rpms and up. Thats why there were no visible leaks idling but it was eating water like mad. He had a Haisley freeze plug kit installed and so far all is well.

 

Awesome. I was going to suggest some blacklite dye, but it's fixed.