E316g Oil Return Options

[TSIMonsteR]

Basically, the M6 bolt holes are beyond use. I was able to helicoil one and it works fine, but the other one, I'm not sure there is hope for. My local machine shop said they could make a plug for it but it'd end up being around $140.

I was looking for other options. Several had popped in my head.

The first option, I could tap the outlet on the turbo for an NPT fitting with a barb on the other side. I could then clamp a rubber hose to that and modify my current return line and clamp the other side to it.

The risk I see with this, being that the turbo is not apart, is metal shavings getting in the turbo no matter how well I clean.

The second option is welding the fitting to the turbo. Would the heat from the welding mess anything up? Would JBWeld work at all?

The only other option I could think of, was trying to drill and plug helicoil it myself and pray that it doesn't leak.

I'll post some pics later. I feel this is a noob question, so I put it in the newbie forum. Thanks for any advice/help in advance. I just hate to see a good E316g go to waste over something like this.

 

[92AWDHX40]

We need pics.

 

[TSIMonsteR]

I know, and I promise they'll be posted tonight or tomorrow. In the meantime, I am putting a 14b on the car.

 

[92AWDHX40]

I had a problem but i had the holes drilled out, then retapped, and i used studs to hold the oil return line to the turbo. Works great.

 

[99gst_racer]

Why can't the other hole be heli-coiled?

Another options could include: Drilling and retapping to a larger thread, or welding the hole shut and drilling/re-tapping M6 again.

 

[TSIMonsteR]

Well, its my fault really. I attempted to extract the broken bolt, but I got off center with my drill and didn't realize it at first.... so I ate into the housing a bit. Not much at all (I think I'm still in denial) and I may be able to save it with some work, but the machine shot didn't seem to optimistic on that option.

 

[92AWDHX40]

Well if you get a pic up i can see if its the same problem with mine, a bolt got snapped off in the housing, so my shop on his spare time opened up both holes. Now i have 2 studs which the return line goes, ,and 2 nuts hold it secure, saved my turbo. Ill try to get a pic up, tonight.

 

[TSIMonsteR]

Sounds like that could work, and honestly, be better in the long run. How much room to I have to play with before getting into the actual oil? In other words, how big did you go on the stud? M8?

Looks like it'll be tomorrow for the pic. The turbo is at my parents house, which is a 40 minute drive.

I won't have time to get over there tonight, but I have to tomorrow.

 

[92AWDHX40]

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