Homemade o2 housing wastegate dump w/ stock housing 1g...

[DSMRevolution]

I know that there were people on here that made a wastegate dump using their stock o2 housing. What I was wondering is what is involved to do this using the stock o2 housing. From what I assume, you would just cut off the wastegate tube where it goes to the o2 housing and weld a piece of metal to seal the hole up. From there you would just weld a open wastegate dump tube to the flange where you cut off the old one.

1. What size pipe would I want to use?
2. How long should it extend?
3. What kind of pipe should I use?
4. From where would I get it?
5. Will it flow as well as a aftermarket o2 housing that would already have a dump tube?

I am sure that I missed something but if you have any information for me please help!!!! Thanks



EDIT: Also Buschur Racing has this:

DUMP TUBE KIT
(TUBING AND FLANGE - U WELD)
Stock #: 30600-BR Price: $50.00

But I am assuming that this is to use a ext. wastegate. Any ideas?

 

[DSMRevolution]

Nobody knows?

 

[Tallen]

mine is going to a local weld/auto shop...
bascially cover the hole and extend the tube a lil....

 

[DSMRevolution]

Originally posted by Tallen
mine is going to a local weld/auto shop...
bascially cover the hole and extend the tube a lil....

What are you using to cover the hole with? Any idea on tube sizes or can you give me some more information on how you cut off the old one? Thanks for the help. I am more worried about cutting off the old one then welding a dump tube on.

 

[InferiorWang]

here's another pic of what you'll want to do. Mebbe it will give you an idea of size.

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Yours should flow as well as aftermarket as long as you do it right and ur tube is the same size as or larger than the tube that currently connects the wastegate to the dp.

 

[GalantVR41062]

good luck welding cast iron...

 

[DSMRevolution]

Originally posted by InferiorWang
here's another pic of what you'll want to do. Mebbe it will give you an idea of size.

Yours should flow as well as aftermarket as long as you do it right and ur tube is the same size as or larger than the tube that currently connects the wastegate to the dp.

Cool thanks for the help again inferiorwang. I like that pic, a bit easier to see.

good luck welding cast iron...

Whats wrong with welding cast iron? I would rater weld cast iron than aluminum since its stronger right?


Also does anybody know if the 2g o2 housing flows better? I was thinking of just using a new one considering it may flow better and its newer. thanks

 

[Boost Junkie]

Originally posted by DSMRevolution
Whats wrong with welding cast iron? I would rater weld cast iron than aluminum since its stronger right?

:shakes head in amazement:

Just wondering, what did you learning in your welding classes?

Welding cast iron often cracks it and is generally not a good idea.

 

[DSMRevolution]

Originally posted by Boost Junkie

:shakes head in amazement:

Just wondering, what did you learning in your welding classes?

Welding cast iron often cracks it and is generally not a good idea.

They really didn't teach us anything in welding class honestly. Everything was half-assed. The teacher, the welders (alot nicer this year), the welds, . I did read a book about welding that they handed out start to finish without being told though! Thanks for the answer though about welding it. Its been done many times on this board and on talk so I assume its possible.


I just ordered a 1.75in. mandrel bent 180 degree j pipe from summit today so I hope that it works out...

 

[zac83]

Originally posted by DSMRevolution


Whats wrong with welding cast iron? I would rater weld cast iron than aluminum since its stronger right?


Also does anybody know if the 2g o2 housing flows better? I was thinking of just using a new one considering it may flow better and its newer. thanks

pretty sure 2g is the same. the lancer housing is the 'high flow' unit that people go after... as far as welding cast iron, dont do it. to 'weld' cast iron, you either have to have some sort of cuprous oxide flux or 45/55 zinc/copper solder to have a weld stick to a cast piece or you have to do something called pinging. to ping, you basicly put 2 pieces of cast or whatever together, heat it up beyond orange hot and tap the seperated area of the piece at the 'crack' with a tool. unfortunantly, pinging is only sturdy when its placing 2 pieces of cast that broke apart from each other together unless you can get them to a temperature that makes cast VERY pliable.

by the way, who had the idea of making an o2 housing out of aluminum? hehe

 

[Kevin Jewer]

Welding cast is tough, I would never try it myself. But FP did a fantastic job of welding a tube to the center of the collector area on my exhaust manifold for a external wastegate. Even with the heat cycling from 0 degrees (its damn cold this winter) to red hot and back again a few times a day, it has never cracked. This piece is a few years old now, and I'm the 4th owner

Another option is to make your own tubular housing. Much nicer than a hacked up cast piece and will flow better. I priced everything needed to about 60 bucks, and welding steel is simple enough. I'm going to make one soon while I wait for my motor. The hardest part is getting multiple angles right so everything lines up acceptably. I'll post pics when I'm done, but dont hold your breath waiting

 

[TurboTerror]

I built my own O2 WG dump out of the stock housing. It wasn't that hard. I used 1 3/4" mandrel bent pipe that I got from a local speed shop for $12. I think that it helped out quite a little bit, Inoticed faster spool, and no boost creep. Welding to the iron wasn't that hard. I did it all myself.

 

[Vinnie]

I'm going to do mine with in the next month I will let you guys know, how hard it is .

 

[DSMRevolution]

Well, I talked to my shop teacher and he said that I shouldn't weld the steel to the cast iron. He said it will crack and it didn't have the right rods etc. I even called a muffler shop and they wouldn't do it but they recommended me to a ever popular welding shop. Best in town basicually. He told me that they wouldn't do it either because the cast iron on exhaust parts is shit and it wouldn't weld up to the steel pipe for the dump tube. He told me that it would just crack. I don't understand how some of you guys did it before if its impossible. Does anybody have any idea what i can do now? Am I just gona have to be strict with the welding shop and tell them to weld it or can i use the mig welder at school? I have no idea on what to do for this project anymore. Should I even attempt to weld anything my self? I am decent at welding but I don't have much expierence. I can weld flat beads pretty well though. Espicually arc welding. Thanks for the help so far.

 

[RabidDonkeyBoy]

its not impossible its just ussually a very dumb idea to weld cast iron to anything. about the only smart thing to do is braze it and hope for the best....

plus depending what O2 you have, perhaps an EVO3 they have a much higher nickel and cadmium chromium contents which make it almost imposible to weld.

AHHAHAHAHAHAHAHAAAA mig weld cast iron and 16 gauge steel exhaust pipe, just do yourself a favor and order the flanges from RRE and mig weld those up http://www.roadraceengineering.com/flangesandgaskets.htm

 

[DSMRevolution]

Originally posted by RabidDonkeyBoy
its not impossible its just ussually a very dumb idea to weld cast iron to anything. about the only smart thing to do is braze it and hope for the best....

plus depending what O2 you have, perhaps an EVO3 they have a much higher nickel and cadmium chromium contents which make it almost imposible to weld.

AHHAHAHAHAHAHAHAAAA mig weld cast iron and 16 gauge steel exhaust pipe, just do yourself a favor and order the flanges from RRE and mig weld those up http://www.roadraceengineering.com/flangesandgaskets.htm

Ok, I am going to order all flanges etc today and ill post pics when I am finished. I didn't know you couldn't MIG weld them together thanks

 

[ItsStockOfficer]

I have made a few o2 dumps by just cutting the wastegate passage open and welding in a 16 gauge steel dump tube, works fine, don't know what people are whining about, on has 30k on it. I use a 100 dollar harbor frieght welder....

 

[DSMRevolution]

Does anybody know what size and dia. that the main pipe should be? The one that goes to the downpipe. I also need to know what bend such as 90 degree etc. Thanks

 

[ItsStockOfficer]

for a custom 02 housing to meet up to a stock downpipe you need a 2.5 inch donut and a 2.5 inch slotted universal flange.

Sean

 

[sergiosdsm]

i dont have a welder and i have asked many local welding shops and none will make me a custom dumptube, i was wondering if anyone was interested in selling one of the ones that they have made , i would be willing to pay up to $75 , depending on the quality, thanks

 

[TurboTerror]

Sorry man. I just sold the one that I had.

 

[Awdboost]

Originally posted by sergiosdsm
i dont have a welder and i have asked many local welding shops and none will make me a custom dumptube, i was wondering if anyone was interested in selling one of the ones that they have made , i would be willing to pay up to $75 , depending on the quality, thanks

PM me with you info and what you want. Will talk about it. My friend a real good welder.