Oldman could you "grade" my porting?

[romeen]

Smooth that O2 housing right out!
This is from a few years ago when I still had a stock turbo and stock O2 housing:

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Like everyone is saying make sure you try and smooth and round/radius edges on your manifold and such.

Nice work. What did you use to get it so smooth?

 

[TimG]

This was a complete waste of time because the Mitsu actuator will never let the flapper arm open to 90 degrees. If you don't believe me, send 20psi to the actuator with a regualted blowgun and see for yourself just how far it opens.

I agree. A lot of the porting done in this thread is just insane. As long as the wastegate hole & port isn't choked up, everything will be fine.

Don't get me wrong, port matching gaskets is usually something desired but most of this stuff is just overkill. I'm not sure about you guys but I HATE porting. I'd rather wash my dog or take a fat, ugly chick out for an expensive meal. All those metal bits are always fun to dig out from your arms and sweep up after you are done.

 

[fourreGsixty3]

Its called a shop vac Tim... Duhhhh Just kidding

Its not too bad porting, I did some just for fun in class. I personally would rather port then take a fat ugly chick out into public let alone to a restaurant.

 

[JusMX141]

I got time, so me wasting 10 minutes porting that out, isn't a big deal.

Now I'm jealous....you have something I don't have!

I wish you lived closer- I'd put you to work in my shop as a porting apprentice. I have at least (12) 6cm2 14B housings that are anxiously awaiting a carbide bit!

 

[JusMX141]

Another porting mod I've done in the past (that I actually copied from a Forced Performance-ported exhaust housing) to help control boost creep is to slightly "D" shape the inlet of the turbine housing (where the manifold mounts) to direct a bit of airflow toward the wastegate hole itself. This way, when the wastegate opens, the airflow will take the path of least resistance.

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It works flawlessly on my buddy's 2G TSi running 22psi with an FP Green.

 

[fwdeclipse]

Hey that looks like my turbine housing. I can tell because of the nasty blue paint on it.

 

[kmoore]

Now I'm jealous....you have something I don't have!

I wish you lived closer- I'd put you to work in my shop as a porting apprentice. I have at least (12) 6cm2 14B housings that are anxiously awaiting a carbide bit!

Honestly. I'm lucky. This isn't my daily driver, and I just got done with a long weekend. So yes, time, I do have.

 

[daren_p]

Another porting mod I've done in the past (that I actually copied from a Forced Performance-ported exhaust housing) to help control boost creep is to slightly "D" shape the inlet of the turbine housing (where the manifold mounts) to direct a bit of airflow toward the wastegate hole itself. This way, when the wastegate opens, the airflow will take the path of least resistance.

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It works flawlessly on my buddy's 2G TSi running 22psi with an FP Green.

Running 22psi isn't ideal to test out if the porting you did helped in preventing boost creep. Lots of setups can run 22 psi without any porting as the turbo won't creep this high (& yes, some still creep even higher). Set the boost to 14psi, then see if you have any creep. If it holds something around 14psi solid, then you know the porting helped. The OP has removed additional material above the WG inlet port, to help prevent boost creep, which is getting pretty common when porting turbo's such as the evoIII.

 

[daren_p]

I agree. A lot of the porting done in this thread is just insane. As long as the wastegate hole & port isn't choked up, everything will be fine.

Don't get me wrong, port matching gaskets is usually something desired but most of this stuff is just overkill. I'm not sure about you guys but I HATE porting. I'd rather wash my dog or take a fat, ugly chick out for an expensive meal. All those metal bits are always fun to dig out from your arms and sweep up after you are done.

Oh common Tim, we all know you don't really hate porting, you just use every excuse you can to get with a plumper

 

[JusMX141]

Running 22psi isn't ideal to test out if the porting you did helped in preventing boost creep. Lots of setups can run 22 psi without any porting as the turbo won't creep this high (& yes, some still creep even higher).

Running 22psi with the 20G that was previously on the car made it creep/spike fairly regularly, which made tuning a nightmare. I don't know if the wastegate hole was too small or what, but we didn't change anything else on the setup (exhaust, manifold, o2 housing, etc.) at the time the Green was installed.

The Green has a 34mm internal flapper with the hole underneath opened to the max, and FP had notched the housing as I had shown in my photo. Even with the additional airflow that the Green has over the 20G, boost creep/spikes were eliminated.

 

[dsmmack]

Nice work. What did you use to get it so smooth?

Standard Abrasives deluxe porting kit.

 

[kmoore]

I'm just wondering, but is Oldman still around? I'd still like him to "grade" it if he is still with us.

 

[kmoore]

Alright, I am just about ready to bolt everything up but I wanted to check with you guys one more time. I am a little concerned with the divider on my manifold. The more and more that I look at it, I think that it is a little brittle. I just don't want it to crack and then chip off into the exhaust housing of the turbo. Do you guys think I should flaten out the divider to make is stronger? Thanks

 

[JusMX141]

The divider was cracked on the 2G manifold that I ported for my '92 TSi. I was just as curious as you at the time, but that's been three years ago and it's still going strong.

 

[kmoore]

The divider was cracked on the 2G manifold that I ported for my '92 TSi. I was just as curious as you at the time, but that's been three years ago and it's still going strong.

I'm just worried about how thin I ported it. Did you port the divider as well (like mine)? Like I said, I just don't want it to crack and chip off and screw a whole mess of things up.

 

[JusMX141]

I trimmed the edges of the divider a bit to match the porting I had done, but aside from that I left the divider alone. I didn't want to make it too thin and risk it cracking further.

I had contemplated flattening the divider out like a GT Concepts manifold (GT EVO Manifold TC-1045 - Turbochargers.com) but I had read where eliminating the divider could effect the flow between cylinders 1,4 and 2,3 so I decided against it.

 

[kmoore]

I'm not talking about totally flattening it out... Just kind of squaring off the top of the divider. Or let me ask you this, do you think that the divider as it is now will be ok? Or should I square it off?

 

[pneumo]

I'm just worried about how thin I ported it. Did you port the divider as well (like mine)? Like I said, I just don't want it to crack and chip off and screw a whole mess of things up.

It's too late now, but others may be reading this so here's what I think;

You shouldn't have thinned the divider. OK?

It's not going to hurt flow by much, so don't worry about it. Since it's thin, I'd recomend squaring off the tip. Don't take too much off, if you do there will be less divider. As long as you didn't thin the base of the divider you shouldn't have to worry about chunks breaking off.

 

[kmoore]

I didn't thin the base at all. I just knifed the tip of the divider... I will square off the tip now.

 

[laserspeeddemon]

I ported my bits myself a LONG time ago. Actually I paid a company to do it and they did the worst job I have ever seen, the lip was still present in most of the turbine inlet and exhaust manifold. It was like the took sand stone to it for like 10 seconds to make it look shiny and then charged me $150.

So I did it myself. Here are the results. Nevermind the crappy cell-phone like pictures.

Everything was gasket matched, smoothened to encourage flow, and polished to a mirror shine. I didn't do the O2 housing since I bought one from 98RedGS (the moderator) and it was ported to all get-out. The only thing I would have done differently was grind the lip above the wastegate to allow for more travel room for the wastegate, still with the extreme ported O2 housing I have 0 creep issues.

 

[blcknspo0ln]

I guess I'll add. Here are my pictures:

BEFORE:

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AFTER:

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DO NOT port more than half way down the turbine exit. I completely messed up my last housing (duh) by doing this. Another thing I have to mention to the new guys is that porting requires patience, not brute force. Picking up a nice carbide bit and letting the bit do the work is the best way of going about it. Another common thing that people do (including myself) is not checking your work every so often. If you don't, you might end up thinning your workpiece too much and making it unuseful. In the case of the manifold, porting the divider wall really isn't that good of an idea, as it will just create turbulance at the collector area. Porting the edges of the collector (where runner meets collector) is a great way to marginally increase the dynamics of exhaust flow.

 

[mach4g63t]

DO NOT port more than half way down the turbine exit. I completely messed up my last housing (duh) by doing this. Another thing I have to mention to the new guys is that porting requires patience, not brute force. Picking up a nice carbide bit and letting the bit do the work is the best way of going about it. Another common thing that people do (including myself) is not checking your work every so often. If you don't, you might end up thinning your workpiece too much and making it unuseful. In the case of the manifold, porting the divider wall really isn't that good of an idea, as it will just create turbulance at the collector area. Porting the edges of the collector (where runner meets collector) is a great way to marginally increase the dynamics of exhaust flow.

I just got to the point where I feel like I've finish up on my exhaust housing on my 16g last night. It looks nice, shiny, and very smooth. Not quite a mirror finish like some of the ones in this thread, but I did remove a lot of material and smoothed everything out. I must say, I actually enjoy porting-- it's fun.... but I did go a good distance into the area where the exhaust turbine fins go. I didn't go very much past where the fins stop at (i checked it every so often) and the most I did was just smooth it out, versus removing material. Did I mess it up? How is this a potential bad thing?

 

[kmoore]

I just got to the point where I feel like I've finish up on my exhaust housing on my 16g last night. It looks nice, shiny, and very smooth. Not quite a mirror finish like some of the ones in this thread, but I did remove a lot of material and smoothed everything out. I must say, I actually enjoy porting-- it's fun.... but I did go a good distance into the area where the exhaust turbine fins go. I didn't go very much past where the fins stop at (i checked it every so often) and the most I did was just smooth it out, versus removing material. Did I mess it up? How is this a potential bad thing?

I believe it creates a turbulence inside that area and decreases flow rather than increase it.

 

[mach4g63t]

Well, if you conside this [........] area to be the area where the fins sit inside the exhaust housing I went about this far.... [........|..] past the fins INTO the exhaust housing. With the right portion being where it exits to the o2. And I just smoothed it out. Do you think that's too terribly bad?

 

[T9S1i]

post a real picture. YOu should stop about 1/2" before you get to where the turbine wheel's outermost edge is in the housing.