The only thing I can see pulling the flapper assembly back a little bit would be a slide hammer. There is a sleeve over the flapper arm that is pressed into the housing, and it took some good whacks to move my old one back into place. I just don't see any spots to hit on the other side without bending/breaking anything. (note: this is not what the arrow is pointing to in the picture)
I just tried prying mine back but it wouldn't even budge; maybe yours is looser and it's worth a shot. Otherwise, I would tack weld a slide hammer to the center of the lever pivot. You could make your own slide hammer if you had a welder, but I don't know what materials or resources are available to you.
To get the old flapper off you need to grind the top "button" away on the flapper itself(seen in pic), then it will be able to come out the other side. Install the 34mm flapper in its place and either tap on the top to mushroom the pin over or put a slit in the center and spread it apart. A center punch in the center of the pin etc. Either way, you want to keep the flapper from coming back off. You can now port the wastegate passage larger if you wish, but be careful not to create the same situation and go too far
I would think it would be easier to port/check/port/check while the 34mm is still removable.
Quote:
Originally Posted by kenamond
I won't be a huge help here, but I've read threads with the opposite situation; the flapper shaft walked out of the housing (yours went in) leaving a gap when the flapper is closed. I forget the complete solution, but you might try searching around for similar threads. You might also try PM-ing Mr Peepers. He's been tinkering with WGs quite a bit lately and, unlike me, might remember the details.
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