big 16g install and porting questions

[linksys42]

Hello, ok im about ready to put my big 16g on and I was going to port the 16g and the EX manifold and o2 housing. What I am wondering is if I should buy new turbo to ex manifold bolts and spring washers and a set of new exhaust manifold studs are they really going to be needed or can I get away with reusing the old ones? And if so what type of studs are the best? This is for a 2g 7bolt. Also I was wondering where I could find some carbide grinding bits locally? Who would carry them? Also I was wondering how much porting takes away from the integrity /strength of the housing to hold up to the extreme heat? One other thing is the 16G install kits really worth the cash. Or should I just piece together all the parts except the SS oil supply line and the j pipe I just don’t want to get this tore down and have to start ordering parts (want to get all my ducks in a row). Thanks

 

[wishihadatalon]

For the bits, look up an industrial tool & supply store.

As for new bolts I would say yes. I have had them stretch on me and back off everyday till I bought new ones. It was not fun at all.

 

[daren_p]

When I did mine I think I just replaced the turbo to mani stud with a bolt & re used the rest but my car had 25k on it when I did the swap, I do remember replaceing all the O2 housing bolts. If you have some miles on it I'd just get them all & be done with it. As for porting, don't think it takes away much of the integrity of the turbine housing as there are 1000's of 16g's out there that have been ported & aren't having issues. For the install kit RRE has a pretty good one, go with their hacker kit, it has everything you actually need.

 

[tsi4ya]

2G Install Kit: 95-99 Eclipse Turbo 16G Install Kitincludes oil feedline, oil return line, J Pipe + Gasket, Oil return line gaskets, Turbo to Manifold Gasket, 02 Housing Gasket and bolts)

Optional Modification: Ported & Modded 34.8mm WG Flapper Valve(On Order)
Gaskets: Turbo to Manifold Gasket

this is some of the things offered by extremepsi. . .all together i think it comes out around 8??. . .

 

[hereitcomes]

I say buy new studs from a suggested buyer. You dont want to be replacing broken off studs, where you could have initially installed new ones. New is always good.

 

[LRS95TSI]

i went with the extreme psi install kit...it came with everything needed...i would buy the bolts, it's always nice to have all new hardware, ppl tend to break them anyways when they do their first swap. use anti-seize on the bolts, and when you install the oil return line make sure to allow some flew, i think i cut mine a little too tight and with engine lift i get a drop or two leak from the oil pan....and teflon the crap out of your lines.

 

[blcknspo0ln]

To add, replace your copper crush washers on the water line banjo bolts. Those things are NOT meant to be reused, in any situation.

 

[linksys42]

and when you install the oil return line make sure to allow some flew, i think i cut mine a little too tight and with engine lift i get a drop or two leak from the oil pan....and teflon the crap out of your lines.

what do you mean? i think i am going to go with the slowboy 2g install kit. looks like they have everything except for the bolts and washers for the turbo to exhaust manifold, plus i am going to need the exhaust manifold studs, and the o2 to downpipe gasket. i think that should cover it?

http://www.slowboyracing.com/more.php?id=93&

 

[Boost Demon]

You take a 50/50 chance of snapping the head to manny bolts, so I'd suggest lots of penetrating oil with the engine hot and after cool down before removal and then add the SS studs there in the event of another turbo swap also. I pieced together my own kit, but I had a few local guys at the time upgrading turbos, so that helped keep the cost down with no ill effects. Try to port everything while you can now, it's free hp and might reduce your chances of boost creep. With porting alone I never had a problem w/ boost creep like most of the EvoIII 16g guys usually encounter, but I ran at almost 20psi daily, good luck.