I'm also on my third VR-4, it's just the way things work. My first one wasn't anything special, it had an electronic boost controller but was limited by fuel cut (0.8~ bar) and made about 290 HP with just a de-cat.
My second one I
went to town on, all the mods above plus good NGK plugs and custom-built downpipes, I tuned that up to a dyno proven 340 HP and 380 Ft/Lbs of torque. It was quite the animal;
By that point the turbos were definitely at their limits and would cause oil overheating if run at high boost for extended periods of time (it was mainly built as a dyno shootout car), it's why I ended up adding switchable maps.
Since then I've seen 400 ft/lbs squeezed out of the turbos (but roughly the same power) but that was boosting to unsafe levels (I think it peaked at 1.6 bar, I personally feel 1.3 is the safe point), going beyond these figures would require better turbos / ignition mods / uprated head bolts etc.
@
Gowf built SWOC, a
450 HP monster with TD-04s but he was breaking half shafts on a regular basis from all the torque it was making. It also had larger injectors and an aftermarket engine ECU.
I also vaguely remember reading that 500+ was achieved by a guy in Russia (can't remember his name) but by that point he was starting to see crank walk (at this point a forged engine would
definitely be required, I would recommend anything after Gowfs levels of power would require forging and definitely stronger transmission parts.
As for tuning, my prices are
here. You'll need a facelift ECU if you want switcheable maps, anti-lag and/or CEL-on-knock. I will have one (or perhaps two) for sale soon, keep your eyes peeled on the UK Parts Section.
Ps. I highly recommend you consider membership, see the link in my signature