Recirculated O2 to external gate O2

[deflator]

So I was browsing recirculated O2 housings set up for the tial 38mm, and I got this dumb idea that I could simply cut up the pipe off the internal wastegate on my Megan O2 housing and weld on new pipe and flanges and have a housing with external gate for half the price.

Now I am not a welder, I know very little about it and I would take it to a shop. I'm not even sure if I should get SS flanges (since my Megan is SS) or if mild steel flanges would be ok. I don't care if it turns out fugly.

How hard would this be? It would all be just getting the right angles on the pipes for the flanges. From the pictures below does this look feasible? Would a welding shop be able to do this for cheap?

And if anyone has more pictures of O2's like the punishment one post them up

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[deflator]

Scaled photoshop, red line around the O2 I have.

 

[420a-t]

It's definately doable, but I'm not sure it would be very cost-effective. There's a 3" o2 housing on ebay that's recirc'd for a 44mm wategate. Why don't you want to dump? Do you like how quiet they are?

 

[z24frank]

I would agree with the cost factor,A shop is not going to be cheap and there is plenty of them used for a good price or just e-bay for that matter.just my 0.2 though.

 

[deflator]

It's definately doable, but I'm not sure it would be very cost-effective. There's a 3" o2 housing on ebay that's recirc'd for a 44mm wategate. Why don't you want to dump? Do you like how quiet they are?

I guess it would be easier to fab if it just had a dump tube. Then I'd just have to have the bottom hole plugged.

I would agree with the cost factor,A shop is not going to be cheap and there is plenty of them used for a good price or just e-bay for that matter.just my 0.2 though.

How much could an exhaust shop charge for a few welds? I wouldn't think more than $40

 

[Iroc_g]

It's definately doable, but I'm not sure it would be very cost-effective. There's a 3" o2 housing on ebay that's recirc'd for a 44mm wategate. Why don't you want to dump? Do you like how quiet they are?

Post a link of this. I searched and could only find a rather odd looking one for a 46mm gate.

Ive never even seen a 46mm gate

 

[andy4g63]

Between the cost of flanges and time for the shop to weld/FIT WG in there, you are going to be very close to the orig. price, nnot to mention the quality. The biggest factor is TIME. It is not just to weld 2 flanges. Wastegate has to fit there. Even with the housing like in the first picture, from a reputable vendor from this site, people had a hard time putting the WG on. Some of them had to call the vendor and after a few guidelines from them went OK... Think about it.

 

[deflator]

It looks simple enough to me. I cut out the pipe, shop welds the flange to it, welds a plate to blockoff the bottom, and welds the other flange to a 45* piece of 1.5" pipe.

1.5" 45* bend - $20 shipped
flanges - $30 shipped

So even if welding is $50 I'm still saving $100 off an SS dumped O2. If anyone knows welding shop prices better please chime in

The only problem is the bung for the O2 sensor looks like its going to ruin all my plans

 

[dsm-onster]

The angles for getting the flanges just right will be kind of off of the tube centers. But I did this:

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I didn't care about the angles being off. It still flows better than an internal gate. I used an ebay o2 housing. If you get an ebay 38mm wastegate, which has workd flawlessly for my for an entire season and for several others, you get the flanges included and pay half the cost for a new TiAL gate. It's really easy to get the gate chamber too close to the alternator or the powersteering pump. And you will likely have to really "tweek" your oil dipstick holder alot.

One thing. Using non-recirculated or 'remote return' wastegating should help turbine flow.

 

[deflator]

I didn't care about the angles being off. It still flows better than an internal gate. I used an ebay o2 housing. If you get an ebay 38mm wastegate, which has workd flawlessly for my for an entire season and for several others, you get the flanges included and pay half the cost for a new TiAL gate.

That's what I plan on doing. I was looking at this one, which looks like a red version of yours. Is this one of those knockoffs that's so close you can put authentic TiAl parts into?

Recalculating angles, I think I could mount the wastegate sideways off the pipe, with the bolt end of the flange pointing up. Plenty of room for a dumptube to make a turn downward, it just won't be pretty.

 

[dsm-onster]

It doesn't need to be pretty. It's a dsm .

You're always taking a chance with ebay parts. That looks like the same as mine. It's the same vendor. I can use TiAL springs in mine. I havn't needed to change the diphragm yet. Which just shows you that chinabay can get some things right.

 

[T9S1i]

you could always sell your o2 housing to offset the cost of a new one...

I dont think recirculating it would be too hard to do, it will just take time and you have to be ready to pay for someones time as they cut and check. Like said above, you have to think about clearances to the radiator/fans, alternator, and ps pump... the dipstick is in the area to, but it can be tweaked.

 

[420a-t]

I had a recirc'd ssac 02 housing, cut everyhting down to the flange, made it 3" mandrel bend, and welded the wastegate onto the o2 outlet. Exhaust work sucks!!!

EDIT: That one on ebay is for a 46mm gate, sorry. I thought it said 44mm. In all honesty, the cheapest way to do it is to get an o2 housing with an external dump, cut the dump off and re-weld a pipe/flange on and call it a day.

 

[andy4g63]

+1 !!!