More boost
#2
Safley maxing out the turbo would be to not max it out lol. Running that little turbo at 22-25 psi would no doubt work, but for how long ? I've seen the k03 with 20 psi and no internals blow the turbo in 6 months, no engine damage. My 02 A4 1.8T has the AMB engine and i'm pretty sure that it has forged bottom end, no need to do it unless your upgrading to a bigger turbo.
#4
I'm in the same boat, i don't know your engine code but mine is the AMB engine 1.8T 180HP. My plans is stage 1 which includes, APR ECU flash which i'm looking to run mabey 15-17 lbs of boost on the stock ko3 sport ( 499.99 ) Aftermarket intake box w/ turbo inlet pipe ( 500.00 ) and a tubo back exhaust not sure which one yet so but those are about 1200 for a nice one. I plan to buy all these together for a nice quick ride that will sound good and hear the turbo nice. That should be your start as well. You could even add injectors at a later time and should help out a little more, and set you up for a ko4 later! This is my idea, hope this helps.
#6
and 25 psi is maxing or coming damn close to making a k03
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