Porting my O2 Housing

[Prodigyman]

Just got my new turbo back exhaust but what I found out that my stock o2 housing has welded in o2 sensor and it doesn’t even work. So I got another stock O2 Housing and thinking of porting it out and slapping it on my new FP Big T28. My Setup currently is 2.5” DP and 3” Catback. What I am wondering is what exactly do I need to port out the stock O2 Housing? I have a dreemel 35 000 RPM tool but what head and such do I need? And generally how do I control what diameter I port out? Do I just do it where the connections are or inside both tubes and such? I really don’t want to spend any more money on aftermarket 2.5” O2 housing.

Your help and suggestions would be really appreciated

 

[Prodigyman]

Anyone?

 

[rowlex]

the bit you need is a carbide cutting bit it.

They are cylindrical shaped or tree shaped, they dont look anything like a drill bit.

I was not able to find any at the local hardware stores you may have to go online or check for an industrial tool supply in your area (where i got mine at $15).

It's going to take you some time with a dremel, I used an air dye grinder and it took me 45 min to an hour. you will port the outlet to 2.5" simply find something 2.5" in diameter and scribe a line onto it(I used the gasket that came with my downpipe). On mine I also ported the exit path of the wastegate, when you look into it you can see where you need to remove material to help increase flow.

 

[UPGRADED2G]

I too have a similar case and since there are so many 02 housing threads around, l'll ask mine here......I have an extra o2 housing and it has been ported, however its not enough to match up the gasket that came my TO4B(mitsu housing). It looks ported to match a 16g. So heres the problem. Even if i open it up to a 2.5(or close) I still will have a misalignmentwhere it comes to that small bridge between the exhaust hole and the wastegate hole. Do i go ahead and port and disregard the misalignment or can i make my own gasket somehow? Where do they sell that material?

If anyone has had this issue when sizing up their T3/T4 gasket with the stock o2 housing, please chime in.

 

[danielbui]

call slowboy racing. they have pre-made gaskets for what ever you need. don't put stock gaskets on they are smaller in diameter and if you cut them they are likley to blowout due to not enough gasket area in certain areas

 

[Prodigyman]

call slowboy racing. they have pre-made gaskets for what ever you need. don't put stock gaskets on they are smaller in diameter and if you cut them they are likley to blowout due to not enough gasket area in certain areas

With all the trouble i have to go through might as well order Hybrid Connection Tubular O2 Housing (2.5") and get appropriate pair of gaskets from SBR...

Performance wise, i mean, does it REALLY matter? If I put the stock O2 housing connecting to my custom made 2.5" DP and then to 3" MagnaFlow High flow CAT and 3" catback with nice magna flow muffler... would i loose too much power? I am installing FP Big T28 bolt on... or if i get that SBR o2 housing it would make big difference? My HP goal is 275 300 WHP and nothing more... its my daily driver after all...

 

[Stapl3]

I used a 1" grinding wheel instead of a bit. Took ~20 minutes and I hogged it the hell out.

 

[danielbui]

With all the trouble i have to go through might as well order Hybrid Connection Tubular O2 Housing (2.5") and get appropriate pair of gaskets from SBR...

Performance wise, i mean, does it REALLY matter? If I put the stock O2 housing connecting to my custom made 2.5" DP and then to 3" MagnaFlow High flow CAT and 3" catback with nice magna flow muffler... would i loose too much power? I am installing FP Big T28 bolt on... or if i get that SBR o2 housing it would make big difference? My HP goal is 275 300 WHP and nothing more... its my daily driver after all...

yes the new o2 housing makes a difference and no you WILL NOT loose power you will gain

 

[TurboAnything]

If you dont have a air supply and a die grinder then dont even try porting cast iron. You will never make it big enough.

 

[oldman]

http://www.dsmloggers.com/products.html

You can also pick up the same die grinder from ebay for like $12 + shipping but I'm glad I bought it from Greg because mine broke and he sent me a replacement immediately.

You should port the turbo and the o2 housing together so you can gasket match both sides to prevent any dead spots. You then want to remove as much of the divider where the wastegate merges back to exhaust as per vfaq. After all that if you feel confident and brave enough, port the outlet to 2.5" like I did to match the 2.5" DP. Happy porting.

 

[Screamin Eagle]

If you have an air dir grinder you should be ok. The biggest thing is having an air compressor beefy enough to supply air to it all the time, those things eat through air. I got my carbide bit at sears. It was in the bit section and it said router bit, but it was carbide tipped. There is only 2 cutting blades on the thing but it took me a total of about 15 min to port it and smooth it out.

 

[Prodigyman]

http://www.dsmloggers.com/products.html

You can also pick up the same die grinder from ebay for like $12 + shipping but I'm glad I bought it from Greg because mine broke and he sent me a replacement immediately.

You should port the turbo and the o2 housing together so you can gasket match both sides to prevent any dead spots. You then want to remove as much of the divider where the wastegate merges back to exhaust as per vfaq. After all that if you feel confident and brave enough, port the outlet to 2.5" like I did to match the 2.5" DP. Happy porting.

Well the thing is my FB Big T28 is already ported... not sure to what diameter but it is. My O2 Housing came of some 99 GSX my exhaust shop told me so its not BRAND new and still have compressor side of turbo bolted in (so I have to unbolt that). Not sure if its a good idea or not to put ported T28 to Stock and used o2 housing...

 

[oldman]

Well the thing is my FB Big T28 is already ported... not sure to what diameter but it is. My O2 Housing came of some 99 GSX my exhaust shop told me so its not BRAND new and still have compressor side of turbo bolted in (so I have to unbolt that). Not sure if its a good idea or not to put ported T28 to Stock and used o2 housing...

I'm not familiar with T28 but it shouldn't be that difficult to remove the hot side from the compressor housing. A CORRECTLY PORTED 2G o2 housing is not that much of a difference from a 2.5" tubular o2, again stressing on "well ported". In fact, when I installed my SBR GT12 with a 2.5" tubular o2 I couldn't match the wastegate path to the turbo side because you can't really port the tubular o2 except for minor grinding on the flange itself so there is a possibility that I might have serious creeping issues when I get the car running this weekend. I plan on putting back my fully ported stock o2 housing if that happens.

 

[Prodigyman]

I'm not familiar with T28 but it shouldn't be that difficult to remove the hot side from the compressor housing. A CORRECTLY PORTED 2G o2 housing is not that much of a difference from a 2.5" tubular o2, again stressing on "well ported". In fact, when I installed my SBR GT12 with a 2.5" tubular o2 I couldn't match the wastegate path to the turbo side because you can't really port the tubular o2 except for minor grinding on the flange itself so there is a possibility that I might have serious creeping issues when I get the car running this weekend. I plan on putting back my fully ported stock o2 housing if that happens.

That’s very interesting... but I just decided and just ordered SBR Hybrid Connection 2.5” Tubular O2 housing. I think this should solve my problems (except ones where I have to spend tons of cash

Thank you for your information guys. I think getting new o2 Housing with right SBR gaskets on my new turbo be most optimal and safe way of doing it.

 

[danielbui]

That’s very interesting... but I just decided and just ordered SBR Hybrid Connection 2.5” Tubular O2 housing. I think this should solve my problems (except ones where I have to spend tons of cash

Thank you for your information guys. I think getting new o2 Housing with right SBR gaskets on my new turbo be most optimal and safe way of doing it.

make sure and order both gaskets. the turbo side is the 2.5 (i think they call it evoIII gasket) and 2.5 downpipe side. when you put the new o2 on make sure and buy lock washers for the dp bolts to ensure fit and no leaks. ask for craig if avalible he's pretty cool.