Please describe this in detail. When it happens, is it under light throttle or a hard pull with the load? Does it feel like the bypass valve is just not closing? If you lay off the throttle and then step on it again does the situation correct itself?
Since the event happens with such rarity, it is difficult to diagnose and or log the event with precision. I have checked and tested the bypass valve, in all tests and videos, working perfectly.
Only because of the logging done and observation with the boost gauge can you tell there is a intermittent "issue"; only really noticeable when towing something heavy. I am working to replicate and narrow down a way to get it to repeat, but you have to be towing heavy for long distances with varying loads to work down the diagnosis. Basically there are rare occasions that boost doesn't build when it should. Really the only way for that to occur is if the bypass valve is not closing. This can be caused by a faulty bypass actuator or the calibration is limiting the amount the Throttle Body can open under a unique set of circumstances. When this occurs, the engine is basically acting and is power limited as if it was normally aspirated from the OEM. You are never lacking power or capability, you just do not have the same power levels with the 5 - 8lbs of boost and it requires the transmission to go a gear or two lower than you would normally have with this kit. Once the load (due to grade or otherwise) reduces, the system works normally again. I drove 360 miles pulling 15k lb travel trailer last weekend and got it to do it maybe 3 - 4 times. It may have something to do with the calibration of the cruise control not downshifting during heavy load changes, but not sure. Seems to do it during user intervention while using cruise control (like pressing the pedal without deactivating CC or manually locking out a gear), but this theory needs more time to test.
Again, no check engine lights or codes and having the issue over 3 or 4 grade increases over 6hrs in the car (~4-6 secs/event) is not something I'm going to lose sleep at night over, but will try to continue to try to replicate when towing heavy. Whipple needs something repeatable and tangible before they can take action.
On the plus side, I towed heavy with significant wind drag in 97 - 100F temperatures this weekend; logging engine PID's at 0.5s intervals. Coolant, Engine Block and Manifold Air Temps were all within what could be considered normal for load and outside air temps.
Once the latest Oil Analysis arrives (hopefully sometime in the next week), I'll try to get posted. We've already put 1600 miles on it since the oil and plug change, it will be time for another oil change before too long.