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I don't get it.
So the wastegate actuator itself is fine. Moves freely, and has pressure on it.
The wastegate flapper on the turbo itself is fine, and moves freely.
You're concerned about the flapper not reaching a "vertical" position from the outside? You do realize that the flapper needs to be completely flat on the wastegate hole inside the turbine housing to seal it and create boost right? The pics you posted in the first post show the flapper close to being 100% shut, judging from the pic itself, but I cannot tell unless I am there or you tell us it won't go forward anymore.
Anyway.
Have you tested the wastegate actuator itself to see if it'll hold any pressure yet? Supposed to hold 7psi, then it opens.
Other than the wastegate actuator, I guess we've pretty much eliminated all the other possibilities other than the boost controller...
I would say, in that case, ask one of your friends if you could put your boost controller on their car for a test, and see if they also get no boost.
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