Ive been building hondas for about 9 years and have always pushed myself on the most reliable best functioning turbo builds. its all in the way you build up to the turbo. And safe for what a stock 4G63 or a built 4G? I know rookhoe who is one of are Moderators was pushing 25 psi on his stock turbo and holding that amount of boost until close to redline. This is also with the stock 9 BOV and wastegate too.
The 4G63 is one mean motor and can take some abuse that fosho
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What engine does my car have?
All currently produced American market evo's have the 2.0 liter 4g63 turbo motor.
How much boost is my car running stock?It depends on the year:
03-04s run 19.5psi at 3500rpm, which tapers to 16psi by 6500rpm
05-06s run 20.3psi at 3500rpm, which tapers to 17psi by 6500rpm
How big is my stock turbo?
Evo's come with different variations of the 16g turbocharger:
03-04 = 16g6 with a 9.8cm^2 turbine housing
05 = 16g6 with a 10.5cm^2 turbine housing
06 = 16g6 with a 10.5cm^2 turbine housing and larger compressor housing
What is stock fuel pressure?
43psi with the vacuun hose off and plugged.
How much does fuel pressure increase when I am boosting?
1:1 = 1psi per 1psi
What size are the stock fuel injectors?
What is the max boost on pump gas I can run?
The best answer to this is that there is no answer, and it's frankly not a good question, though it's often asked. Octane is definitely the main determining factor for how much boost you can run, but there are still many other factors, such as the mods you have, the turbo you have (differs between years)
How much boost can my stock blow off valve hold? When do I need to upgrade?
03-05 = Efficient to 13psi, but the turbo runs 19-20psi stock, so the BOV still works, but it's not optimum. It's a good idea to upgrade to a PROPER RECIRCULATING BOV (actually called a DV = diverter valve) as soon as you up the boost. It is considered a stage 1 mod on 03-05 USDM Evos
06 = Efficient to 24-25psi. No need to upgrade until running more than 25psi (requires race gas or alky injection) on the stock turbo or until you upgrade the turbo.