Cleaner way to get a WG actuator to work on a Cyclone manifold

[Dallas J]

I had a problem with the original cyclone actuator leaking pressure pretty much defeating the purpose. I noticed this after manually closing the butterfly valves, plugging the hole, and watching the reaction. If the actuator is bad the valves will open up. If its good the valves should hold pretty much indefinitely.

Since theirs no available replacement I started going through the research of finding other options. I saw a thread about using the stock wastegate solenoid, but really didn't like the mounting solution.

I also thought about using an electric solenoid. I found a few on McMaster-Carr, like this one, McMaster-Carr. The problem is the maximum force is pretty low. I'm just not sure if it'll be enough to over come a return spring while maintaining a fast response speed. Also, reliability was a concern.

Since we know the wastegate actuator (WGA) cant handle the rigors of under-hood high temp use, I decided to figure out what I could do about the mounting solution. With the manifold on the car I could position the WGA in a suitable location, all I needed to do was make a bracket and get everything mounted up.

I started with some angle iron I had sitting around. I trimmed both edges to get it to fit between the timing belt cover and manifold. Then I used the stock actuator to get the hole pattern in the bracket.

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Holding the WGA up to the bracket, I found the distance I wanted to mount it and market the bracket where to cut.

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Here's the bracket bent with a hole drilled in it for the shaft from the WGA.

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Next I cut and bent one of the tabs that looked like a good mounting solution, drilled a hole between the 2 brackets and bolted it together. The other tab just got cut off and ground down for a cleaner look.

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Here it is showing everything fits. The fuel line sits just right above it with the AN fuel line tilted just slightly upwards.

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I still have to make an adapter to fit the shaft to the butterfly, but I have a pretty good idea for that. I threaded the WGA shaft and Im going to drill one of the flat sides and use a long set screw. This will give me ajustment without much possibility of slipping.

Ill post up more pictures when I get the adapter from shaft to butterfly made.

-Dallas J

 

[Rob10_99]

I'm about to do the exact same thing after I get mine cleaned up and port matched a bit. I noticed you dont have the U channel connecting the pieces together, Right next to the WGA where those two loose bolts are. I assume you took it off for a mounting solution?
Good write up, I should get some in action shots of what I've got goin' on in this part of O town,

 

[Dallas J]

Actually the u-channel bracket is normally in place. I just have it out of place cause thats where I route the wiring for the injectors and Cam angle sensor. Theyll go back in place when I put it back on the final time. As it is right now, Im taking it off and on very frequently.

I just realized you were from the same neck of woods as me. If you need to see the bracket or need help with yours you're welcome to come on by

-Dallas J