blocking off wastegate portion of HX35 turbine housing

[ed1380]

I haven't seen anyone else try this. Hopefully the gains are worth the effort. (11pm-4am)

Removed the flapper lever. Kept the actual flapper for later.

Started with a piece of steel. Cut roughly to size and file the edges to make them parallel. Found a socket that was the same size as the turbine housing. It just took 10 seconds for a perfect bend.

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fitted it in place.

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some more final touches

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Tacked in place.

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Except Only take in 2 adjacent sides. Cast iron expands alot. You could hear it cracking after welding.

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Welded slowly. About 1/4" at a time, then a 5 minute break that I used to clean the slag for the next bead. The first 2 beads were the best.(bottom) The rest I tried different power settings and feed rate. (ugly)

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Flux core doesn't look pretty, and I was getting tired

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Gave it my best and the last bead was also good. Took 2 hours to weld that.

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Going to clean up the welds in a few hours, and cut down the flapper for it to fit in the hole. Then weld it flush with the inside of the housing.

 

[Alex7747]

thats a huge socket . great job though!

 

[BoostedBeaver]

I would like to see the finished project after you get some sleep of course. I am also interested in that socket size??? Not sure if anyone has done this before and I think Justin may pop in later.

Robert

 

[mike96]

Just curious, did you do this so that you could dump to atmosphere using the internal WG or so you could use an external WG off the O2 housing?

 

[BoostedBeaver]

There is no 02 housing (to my knowledge) that will bolt up to the stock holset hotside, so running a wastegate after the turbo is not easily possible. Venting to the atmosphere is also not his idea unless I am reading it wrong. Here is the quote :

Going to clean up the welds in a few hours, and cut down the flapper for it to fit in the hole. Then weld it flush with the inside of the housing.

I could be reading it wrong as I do tend to do that sometimes.

There is another plate that bolts to the housing with only a V-band outlet for the exhaust. I am guessing this is to keep the exhaust gas flowing smoothly? Without the plate, the exhaust gas would enter the "shelf" created buy only welding the flapper shut. I do not know if this would help or make any more difference than just welding the flapper shut and leaving the passage open? Maybe the OP has another motive or better understanding of the situation than me??

Robert

 

[DOHCeclipse]

I do not know if this would help or make any more difference than just welding the flapper shut and leaving the passage open?

I would like to know this as well, I was just going to weld my flapper shut but I didn't know if it harm anything with that passage open.

 

[tkrPerformance]

I have done this on a lot of pte turbos for people.

 

[e85_4g63]

Just for reference, Holset makes a 12cm^2 non wastegated housing, it's around $250...

12cm2 Non-Wastegated Turbine Housing (Short Outlet)

 

[mike96]

There is no 02 housing (to my knowledge) that will bolt up to the stock holset hotside, so running a wastegate after the turbo is not easily possible. Venting to the atmosphere is also not his idea unless I am reading it wrong. Here is the quote : I could be reading it wrong as I do tend to do that sometimes.

There is another plate that bolts to the housing with only a V-band outlet for the exhaust. I am guessing this is to keep the exhaust gas flowing smoothly? Without the plate, the exhaust gas would enter the "shelf" created buy only welding the flapper shut. I do not know if this would help or make any more difference than just welding the flapper shut and leaving the passage open? Maybe the OP has another motive or better understanding of the situation than me??

Robert

There may not be an "on the market" readily available O2 housing that bolts up however, by doing what he did he now has the option for doing a custom O2 and he could go either way..

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[BoostedBeaver]

There may not be an "on the market" readily available O2 housing that bolts up however, by doing what he did he now has the option for doing a custom O2 and he could go either way..

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I understand which is why I stated it is not easily possible. The OP could hack the stock flange and then build whatever he may like. He stated he plans on welding the hole shut which would make a custom 02 pointless as there will not be a provision. I am sure the OP will chime in with the knowledge he has gathered and what drove the need to find such a large socket.

Robert

 

[ed1380]

Well I slept through all my classes. Ill be getting my rasp from mcmaster and cleaning that up soon.

I'm blocking the wastegate hole because my manifold has a place for the wastegate. And I didn't want turbulence from the exhaust entering the wastegate portion of the housing. I will be dumping unitl I get tired of it and have time to weld a return in the downpipe.

Wow I didn't know they made that. Well if this housing ever cracks I'm not too worried now

My dad is a semi mechanic so he has big sockets. You can use a smaller axle socket and just flatten it out as needed.

 

[TWOpointFORliter]

Just for reference, Holset makes a 12cm^2 non wastegated housing, it's around $250...

12cm2 Non-Wastegated Turbine Housing (Short Outlet)

You just totally made my day. I'll have to order this ASAP.


To the OP nice work I was planing on doing the same untill that link was posted.

 

[ed1380]

You might be able to get it cheaper from the dodge forums. Now I'm just thinking I should have just sold mine and bought a non wastegated one

 

[BoostedBeaver]

Well I slept through all my classes. Ill be getting my rasp from mcmaster and cleaning that up soon.

I'm blocking the wastegate hole because my manifold has a place for the wastegate. And I didn't want turbulence from the exhaust entering the wastegate portion of the housing.

Wow I didn't know they made that. Well if this housing ever cracks I'm not too worried now

My dad is a semi mechanic so he has big sockets. You can use a smaller socket and just flatten it out as needed.

Great idea to stop turbulence in the exhaust stream. I do not think you will have a problem with your housing cracking and I think you will be happy with the turbo. Quick question, Do you plan on knife edging the inlet of the turbine housing inlet or running a truly divided setup??

Robert

 

[ed1380]

Great idea to stop turbulence in the exhaust stream. I do not think you will have a problem with your housing cracking and I think you will be happy with the turbo. Quick question, Do you plan on knife edging the inlet of the turbine housing inlet or running a truly divided setup??

Robert

I will run a true divided setup sometime next year. I'll be making my own manifold like Mr. Peepers. For now my ram horn will have to do. I might just knife edge it and get a non wastegated housing when I go TS.

 

[bastarddsm]

I've done this to mine. You should have welded it with stainless wire. It doesn't crack then.

 

[99gst_racer]

^^^ Agreed. 308L is the best wire to use on a turbine housing.


Nice work though. I considered doing this to my 10cm housing, but I ended up just welding the flapper shut and leaving that gap there.

 

[ed1380]

I've got a quick question. Will a 1/8" washer work for the hole? I found one the right size so I don't have to grind down the flapper(3/16")

 

[99gst_racer]

1/8" should be fine.

 

[ed1380]

I actually just measured it and the washer is 3/32" and flapper is 1/8". Oh well. Flapper it is.

The flapper had marks that were exactly where I needed to cut

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Grinded it down to size, and it fit perfect but I wanted it snug. So I peaned the edges and tapped it in the hole.

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I decided to keep the hole for my egt gauge. I removed the collars from the sensor. I'll later weld in a support

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Once again welded a little at a time, cleaning it between beads. Also welded the hole for the flapper rod.

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I didn't get to cut down the turbine welds yet.

 

[ed1380]

I finally got around to it. Tried a hss single cut burr and it didn't do anything. Bought a double cut carbide burr and it cut through it with ease. Ordered a cone shaped burr so I can port it also. I did find cracks so those will be rewelded.

Here's how it looks like now.

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[turboglenn]

Nice work, i'ce had to dothe same on some turbos off a familia engine and something else before.. the engines were al JDM swapped into USDM cars and since they didn't get the 02 housings with them i even have to make thouse. but again very good work!