Outer Limits 4x4 Board

What are the max boost pressure that the turbo and engine can handle it is 10 psi stock un intercooled id keep the boost at 15 or under but dont want to strain the turbo to much

A 2.5 inch exhaust and a minor pump tweak will give a boost of 11 to 12 psi, which I would call the limit without an intercooler, for longevity I'd say your call of 15 psi would be about the max..
I never checked the turbo outlet temps though.

15 psi would be good enough for what i want i have been spoilt with my old disco 300tdi 20psi boost
it went quite hard
not going to that extent with the deo though

Ran 20psi in my deo for over 100K with IC, EGT gauge, 2.5" pipe. If you go over stock boost you need to block off the overboost valve on the back of the plenum chamber as it vents into the crank case breather and will over pressurise the crankcase and blow out the rear main seal, found that out the hard way. If you drive it to the egt gauge no problems and it will pull like a frieght train. The only problem I had was to much touque as it snaped the spring hanger out of the chassy towing 1ton trailer uphill.

the standard turbo on a rodeo will only produce 14 psi max with the waste gate disabled. I used to run mine at 12psi but i put an intercooler on it and had it dyno tuned. Went from 72fwkw standard to 89rwkw and torque went up from a factory specified 220nm to 350nm

Your actuator spring must have been weak then.