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Why not put on your old tip and see if you still have the problem, if you don't u need to tweak the map or run a boost controller to control the boost spikes, this still doesn't explain the big difference between the actual vs requested boost, u are getting more boost than the ecu requests, I can only guess the new TIP has meant your turbo should be running lower duty cycles to create the same amount of boost because of the increased airflow.
Thats fine if thats the case and the TIP needs an mbc to work properly. But is that the case?
So should all 3" tips be fitted with an mbc?
Personally Id remove the TIP to prove/disprove its causing the surge. If thats the culprit then fit an mbc and happy days.
As much as JJ must be pulling his hair out this thread has become a good testing and development piece. I think we`re all interested in this as the TIP sounds excellent and makes a solid difference.