Cool. I wouldn't have thought to run a pressure test while hot. I'll check the bouncing carbs thing too. I had to use silicone tubing for boots as the Rage cage ones fell apart in a hurry. And I do have an airbox support to the tunnel to limit movement.
Bryce, Did the Frogskin not work with setups you've seen? Initially at first testing I ran it with no filter whatsoever on an open hill and it didn't seem to make a difference. But it has all kinds of issues and I've never built boost above 4 lbs, so maybe it will suffocate it once everything else is taken care of. I do plan to run a 3" flex tube up to a 2 1/2" K&N cone filter for powder. I question the tumbling air through the charge tube as well for performance, but I'll make that change if I can get it to build boost. The line to the controller isn't kinked, however it does make a tight bend, but no so much that it would limit pressure.
I question the aero controller diaphragm as well, even though it is new. I tried using a carb pop-off guage/pump to see if it would hold pressure, but it leaks out as fast as I pump. Maybe its just because I can't keep enough simulated pressure fast enough to get the rod to move. I did play with the controller screw when riding and it made a substantial difference with how fast the boost came on. But my 4 lb max boost isn't all that impressive.
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I also read something with the stock XP pipe about cutting out the stinger? Is there a mod like that to be done with a rev pipe while I'm making a new attachment? My pipe has all the seams welded and all I saw was a 2" straight pipe inside at the end.
Thanks guys. Hopefully, I can make this work. I'm don't want to waste another season tuning.