My Custom External Wastegate and Dumptube

[Hubbard 0]

Inspiration (if you can call it that) for this project was all based around a particular exhaust that I found on chitowndsm. I knew I wanted to go external for the Holset and when I found a 46mm gate I jumped on it. Not until I just tried to lay it in the engine, did I realize the true size of it.

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I laid it in the engine bay to get an idea of how I'm going to make this work.

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First thing to be done was move the fan to the other side of the radiator and trimmed the piping on the intercooler inlet so the pipe would run closer to the radiator.

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Not to deviate too much from the waste gate setup, but here's a shot of the fans. Initially I put the aftermarket fan on the other side, but I found out that I was crushing the housing causing the blades not to spin and kept blowing fuses. I then bought 2 fans from Summit, a 10" and 8" and it fit fine.

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Comparison of the old setup and new, one peice O2 housing and downpipe.

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The gasket that came off my turbo and my new gaskets from AMS.

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Here is where the fun set in. Cutting up tubing and mocking it into place gets seriously difficult when the welder isn't at hand. Not to mention, I had the first tube mocked up and marked for welding but once I got to class, my dumbass put the downpipe in the sandblaster and blew away all my marks. I eyeballed it back into place and truly got lucky.

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This shows the beginning of the dump tube. Without fixing the IC pipe earlier, this wouldn't have worked.

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Now mocked up.

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Finished weld. I learned an important lesson about the difference between being able to weld a nice bead for a class project and laying a nice bead on an actual part. I would have liked to do a better job, but overall I'm more then happy.

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Dump tube then had to be wrapped.

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Let me know what you think.

 

[Imback]

Over all it's good. I personally would have tried to find a straight piece then weld the bend that goes into the the downpipe. As for the welds go there alright better then some of the others i have seen floating around this section.

 

[Hubbard 0]

I think I see what you're saying. Basically, build it from the bottom up instead of the top, down?

As for the welds, I did this in my welding class which would put me at about 4 or 5 weeks of training in TIG. I plan to get a lot better in my next class and hope to make an intake manifold.

 

[1timehondalover]

I'm impressed you found a spot to mount that massive SOB. Definitely a good job for developing skills.

 

[Killa_dsm]

That looks like a pretty tight squeeze in there, but great job getting it to fit.

 

[awdrst]

Looks pretty good. One suggestion I would make is that on the one piece downpipe where there is that sharp angle I would suggest trying to get a mandrel bend or make it with a few pie cuts. You will get a smoother exhaust flow in the end. The welds looks good for someone who has been only doing it for a few weeks. Practice will only make you better. Good job overall.

 

[Hubbard 0]

The pictures must make it seem like more of an angle then it really is. That angle is pretty small and I'm not worried about it being a restriction at all.

 

[99gst_racer]

Fine work.
You'll get better at it ever time you tackle a "pipe fit and weld" project.

And you're really going to enjoy the recirculated wastegate. Don't get me wrong - I love the sound of a dumped gate. But it does get old after a while, and it's nice to hear the turbo spool for a change.

 

[Project2G]

Nice job. I made mine exit the front bumper but it would be nice to recirc it since at times the sound does get old.

 

[Dsmj89]

Looks very nice bro. Great job.

 

[vanilla gorilla]

Great job! The welds look good!

 

[Cmele89]

wow dude come do that to my car your welds are great .. better than mine of coarse mine look like herpes

 

[Hubbard 0]

Well it's been close to a year now since I finished this and I can happily say everything still works great. No leaks, cracks or anything.

I have since relocated the alternator and a 50 trim goes on next weekend.

 

[pj91gsx]

i have the same cup as you in the 1st pic.