DIY External Dump O2 Housing...

Tallen · 07-03-2003, 12:21 PM

DIY External Dump O2 Housing

Purpose: To help eliminate boost creep and make lots of noise
under boost.

Disclaimer: Do not try this at home, serious injury could
result. I am not responsible for anything stupid you do.

Tools:

-Die Grinder (Dremel if push comes to shove)

-Cutoff wheel for Die Grinder (Hacksaw can be subsituted)

-Hacksaw

-Grinding stones

-1" ID steel pipe or similar

-Welder or $ to get the dump pipe welded on

-O2 Housing (I suggest a spare one)

1: Cut the O2 Housing as shown by using a Hacksaw or Cutoff
Wheel.

Tallen · 07-03-2003, 12:22 PM

2: Now it's time to open up the O2 housing. Using the Hacksaw
or Cutoff Wheel, cut off the piece with the rounded top (highlighted in red
on the picture).

Tallen · 07-03-2003, 12:23 PM

3: Now get out that piece of steel pipe. Using a pipe bender,
slightly bend the pipe. You can also do this by putting the pipe in a vice and
giving it a good tug. Cut off a piece of that curved pipe about 5" long.

4: Getting the pipe to line up correctly, while avoiding the
O2 sensor bung can be tedeous (unless your modding a 1G O2 housing). One side
of the pipe must be cut at at an angle to get it to properly lineup with the
cut on the O2 Housing. Do not worry too much about any gaps. Worry about the
O2 sensor clearances! The welding will take care of any gaps! It may take some
grinding of the cast iron to get the pipe in a good groove.

Tallen · 07-03-2003, 12:25 PM

5: Now cut the end of the pipe facing away to an angle so
the exhaust will shoot downward a little more.

6: You're done!...Unless you can weld! Be sure that whoever
is doing the welding fills the hole in the O2 housing first (highlighted in
red). Using a Nickel rod, weld the cast iron and the steel pipe together. Thats
it! Now consider porting/polishing the piece too.

Copyright Matt Szabaga 2003. Use it,
copy it, whatever, as long as you give me credit for my work.

Tallen · 07-03-2003, 09:38 PM

$30 - O2 Housing
$0 - Pipe setting around garage
$25 - Welding
$55 TOTAL!

In response to an email I got: I really suggest you get it welded and NOT use JB Weld. JB is tough stuff...but come on! If i get enough people bugging me, maybe I'll test out a JB'd one.