Having problem mating 3" downpipe to stock Turbo....

[Street Lethal]

We just recently purchased Pacesetter's ceramic coated header, and downpipe.... but kept the stock turbo in tact (95-GSX). Now, we're obviously upgrading to a bigger Turbo in the future, but for now, we're stuck running with the stocker.

The car now has a full three inch exhaust, and everything went on rather smoothly....except where the downpipe meets the stock turbo. We were able to mount it, but securing it with 1/4 inch nuts is impossible. The welds on the downpipe are in the way of making it seat properly. I was going to file the welds down on each side of the flange to "make" the nuts seat, but am having second thoughts.

I'm not sure what you call that part of the Turbo (where the O2 sensor is located), but is there an aftermaket piece that would adapt to the larger downpipe.... or do we simply need a bigger Turbo "now". Should I just grind down the welds on the downpipe's flange (not all the way around, just where the nuts fasten down), or should I discard this concept.

If a new turbo is needed, any suggestions?

We'd really like to run the stock Turbo, at least until spring... so can anyone give some good advice?

Thanks,

SL

 

[BlueTurboSpyder]

Hi. I think you idea of grinding or filing the welds down is a good idea but be careful. Also, it would be a good idea to get some high temp paint once you file your welds down to prevent rusting. Changing you O2 housing (thats what its called) or turbo wont fix the problem your having. Have fun

 

[Street Lethal]

I think you idea of grinding or filing the welds down is a good idea but be careful. Also, it would be a good idea to get some high temp paint once you file your welds down to prevent rusting.

Good tip, thanks. Yeah, we pulled the down-pipe off and filed down the welds just enough for the nut to seat properly. But before we bolted it down, we gave it a shot of some high-temp paint... then applied some more, after it was bolted down.

So far, so good.