It's been a little while since I've updated but that is mainly because I've moved to Texas now.  This move gave the perfect opportunity to do a bit more comprehensive long-term durability testing and the results are good.  No issues with the engine performance or the added components.  No check engine lights have appeared at all since after first install, and gas mileage has remained about stock.  290 miles on about 2/3 to 3/4 of a tank each fillup on a loaded car going between 65-70mph.  286 miles on 9 gallons of gas comes out to about 31mpg, very good for an AWD car.   As compared to the last road trip I took it is up about 1.5-2mpg but some of that could just be that the car is more broke-in now.  What we do know is that the performance can be increased without sacrificing the driveability and economy just by providing a turbo kit that operates at stock boost levels using just the factory tune.

Our next step will be to continue the integration of the internal wastegate, then more dyno testing to see what an aftermarket exhaust can do on the stock tune.  Finally, we will then move to the next stage where we attempt to partner up with a tuning company and produce a safe tune to allow the engine to go well above stock boost pressures. 

So far we have good news to report that we have had no problems at all with the upgraded hardware running in our test volvo.
We have focused our attention on engine management, heat and mechanical reliability.
We did initially have a leak on the oil drain tube due to an o-ring not seating correctly but it seems a small change in angle solved that nicely and there has been no further signs.

Gas mileage seems to be about the same under normal driving but the tendency to want to go a lot faster now has reared its ugly head and consequently we are consuming a bit more.  The fuel economy average on commutes without spirited driving is about the same as one would expect with the bulk of the driving in the lower rpm ranges and exact same boost settings as stock.

We are going to revise the manifold one last time and finish integrating the internal wastegate over the next few weeks and then we should be complete.
Thanks for your interest and check back soon.