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Tapping a 16G Compressor Housing For a Pressure Source

Let me start of by saying this: if you do not know how to tap metal then I strongly advise you not to try this on your own compressor housing.

Buy some Aluminum About 1/2" thick and practice first, practice makes perfect you know!

• All Pictures are in sequential order after reading the instructions.

Let me start off with a list of parts and tools:

Tools:

-10mm Socket or Wrench

-12mm Socket or Wrench

-Large Snap Ring Pliers

-Letter R Drill Bit

-1/8" - 27 Tap and Tap Handle Wrench

-Wrench for Fitting

-Power Drill or Preferably a Drill Press

-Gunk Carborator and Parts Cleaner Large can (Optional Found at Advance Auto)

-Teflon tap or Teflon sealant (Optional)

-Aluminum carbide bit and 1/4" Air Grinder (Optional)

-Dremel with sanding bits or stone polishing bits (Optional)

Parts:

-1/8" - 27 NPT Barb Fitting - Summit Part # GAR-J9027

Turbo Disassemble

First we are going to start by disassembling the turbo; don't worry this is the easy part. Pull the pin that holds the wastegate actuator arm to the flapper valve and pull the arm off of the stud. Now use a 12mm wrench to remove the bolts holding the wastegate actuator to the compressor housing. Next, use a 10mm socket and remove the clamp holding the turbine housing to the main housing. Carefully remove the turbine housing and set aside. Now at this stage you will want to be very careful, since the turbine blades are now unprotected. Now on to the last step of disassembly; take the snap ring pliers and remove the large snap ring. Be patient at this part it takes some time and muscle to get the ring off. Now just slide the compressor housing off of the main housing, it's in their with an o-ring so the fit will be tight but don't worry it will come apart. Be sure to set the main housing in a safe place so damage will not come to it.

Tapping

Now onto the actual difficult part. Using the drill press and the letter R drill bit, drill a hole in the compressor housing where an existing screw hole is located. (See Picture) Be sure to go all the way through to the compressors outlet. Now take the 1/8" Tap and insert it into the Tap Handle wrench. Nows the tricky part, carefully start to tap the hole you just made, make sure that you are going straight both horizontaly and vertically. On a side note since we are working with aluminum make sure to go very slow and use tapping oil. If you don't go slow and use oil, the aluminum will heat up and bond to your tap and destroy it.

Now,test fit your fitting into the taped hole you just made, if it fits then your done.

• These next few steps are optional but highly recommended! If

not doing these steps just skip this section.

Cleaning and Deburring

Using the Dremel and the apporpriate bit clean the metal burrs and smooth the inside of the outlet, clean up as much as you like and smooth out as much as you like. Now that everything is cleaned up take an airhose and blast away the metal shavings. If you have purchased the parts cleaner you can just put the whole housing in the cleaner; let it sit for 20 minutes or more, remove housing and wipe away excess cleaner doing so will also clean the dirt and oil off. If not clean enought just repeat the previous procedure. Use some water and rinse off the housing any cleaner that still remians will turn white and will drip off. Wipe off water and your done!

Reassembling Turbo and Installing Fitting

I suggest that you wait until the turbo is completly assembled before attaching the fitting. Now to reassemble the turbo just reverse your steps that you used to disassemble it. *Once again be patient with the snap ring it will take some time to put back. After everything is back together now is the time to install the the fitting. *This step is not need but mearly a precaution; using teflon tape or teflon sealant put about two wraps or a drop or two on the fitting and slowly screw it in. Using a wrench tighten it down until you feel comfortable just remember not to over tighen it since, you could possible crack the Aluminum or strip the threads.

That's it your done, congratulations. If you have any questions please feel free to Pm me.

Enjoy - Ndsti 20:14, 1 January 2008 (EST)

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