Turbo/Exhaust/Creep/20+psi question

[oldman]

I'll post up some pics tonight old man, does anybody have a picture of what the wastegate exit should look like as with every comment i get a lil more confused about this part of the port job..

If memory serves me right you have an o2 eliminator downpipe and this is why I told you not to port too much on the the wastegate exit, you want to match the turbine flange to the downpipe as perfectly as possible. If you had a portable o2 housing like stock 2G or EVOIII, I would have ask you to open up the wastegate exit as much as possible then match the o2 housing side.

Keep in mind while you do this that you want the flanges to mate as perfectly as possible so take off just enough and not more.

 

[Chadillac2000]

okay gotcha, yeah well im gonna go finish up porting up the inlet to make the air an easier path to the wastegate, i think im gonna mirror polish it as well since i have it off, then im going to gasket match the exhaust mani, ill have pictures later so you can rate my job oldman

 

[Chadillac2000]

Alright not near done just wondering what you guys thought of the port job of the inlet so far, and if you think i need any porting done to the wastegate flapper area, and also dont know if this could have had anything to do with my creep or anything, but the turbo to o2 housing gasket that slowboy sent me covered about 1/16th or so of the actual wastegate flapper area so I trimmed the gasket to mirror image the other, but here are the pitures

 

[oldman]

Flapper - A-
Wastegate entrance - B+
overall turbine inlet - C-

Are you using a dremel to do this? Looks like you got discouraged because you realized it was going to take a lot of time using the dremel. I suggest getting a $10 electric die-grinder and a $12 1/4" cylinder shape carbide burr, a dremel with diamond burr will do the job as well but you have to be patient. My biggest criticism would be that you need to open up the entire inlet to the flange instead of leaving the step there, compare yours to the picture on last page and you should have answered your own question. Now go and finish it right.

 

[Chadillac2000]

im wasnt finished yet, was just making sure that I didnt need anything done to the wastegate flapper and that i was on the right track as far as the entrance is concerned, I plan on evening everything out and making a more direct flow to the wastegate, and im using air tools, with a carbide bit on it, hasnt taken that much time, im gettin some titanium bits later to try and get those damned bolts out, what could i do to the flapper to make it an A+?

 

[oldman]

what could i do to the flapper to make it an A+?

Open it it just a bit more and smooth out all the rough surfaces on the path wall and I'll re-consider.

 

[90blacktsiawd]

as far as the flapper the flapper already opens parallel although i'll probably port some more just in case

Just beause with no o2 housing on the flapper open parallel doesnt mean it will once you bolt the o2 housing back on. Just something for you to check out while you have everythign off.

 

[Chadillac2000]

Alright guys after about 3 hours of porting and messing around with this thing i think i got it pretty good and i learned alot for my first time porting, but OLDMAN can you please rerate me and tell me if this is up to your standards, and the pics dont do it justice its alot shinier than this also took a little more off the flapper so that it would open up parallel, even used a level to double check that it was opening at a 90 degree angle

 

[oldman]

Flapper - A
Wastegate - A
Inlet - B... maybe B+

Sorry I don't even give myself A+.

What happen to the other side of the inlet? Why is the step still there? Port it so that the flange and housing become one but make sure you use common sense and keep it consistant with a cone shape. Can you still feel your fingers after all the vibration? Still up for porting the manifold? Oh, make sure you wear a goggle.

 

[Chadillac2000]

okay im gonna make the flange and the housing one as I know see how only the side where the wastegate is does that, then i might polish it a little better, my fingers are toast man i cant feel them at all, definitely waitin to do the wastegate tomorrow, it sucks, but im gettin better at this i think haha plus tonight i can pray that all this work wasnt for nothing

 

[rowlex]

damn dude your inlet porting puts mine to shame... I got bored after about 20 minutes and put it back together ... Almost makes me want to take it apart again.

 

[Chadillac2000]

Okay done with my turbo porting for the day, dropped the mani so thats my goal for tomorrow, the material is alot harder than that of the turbo, so its gonna be a much longer day, but im happy as how my turbo turned out, hopefully it will get rid of my creep, ill keep you guys posted and the turbo again is a hell of alot shinier and smoother than it looks in the pictures, its mirrored and smooth as anything just i guess the flash screwed that up, OLDMAN another rating please...

 

[oldman]

A+ for the inlet, I couldn't have done it better myself. In fact, I'm using this picture from now on instead of the other one. Isn't porting addictive? What you have done today not only should cure your creep, it will also improve spool up time. Paper trace the flange including the bolt holes, cut it out, and past it on the manifold collector so you can get a perfect match. Once again, you have made me proud.

 

[Chadillac2000]

thanks so much man I really appreciate that, and yes porting is addicting, i now wish that I woulda saved my 50 bucks from slowboy and done it myself, I cant wait to get with my exhaust manifold, which has been untouched and still holds the 6cm hole, instead of the 7 that it needed, I have found so many places where the air has just been hitting barriers instead of smoothly flowing throughout my system, again ill post pictures of my manifold tomorrow, and ultimately whether or not this solved the creep

 

[Chadillac2000]

alright think im done with the manifold but guess ill be sure after OLDMAN gives me my rating, , i didnt notch out the center divider as after doing some research i found out that directs air and serves a valuable role in the manifold design, it is a perfect match to that of my inlet, so I should be flowing much more smoothly between all this, didnt touch the runners as i was going to see what you guys thought i should to do them if anything, I dont see any purpose since my head isn't ported at all...ported not only the ring but also ported it to a full 7 centimeteres, and i used the paper trace method to match up the inlet and the mani

 

[oldman]

i didnt notch out the center divider as after doing some research i found out that directs air and serves a valuable role in the manifold design

You are absolutely correct on that.

B+ for it not being round, must be your paper cutting skills. Now go bolt them on and don't post back unless it works.

I did enlarge the runners by about 2mm and 2in deep but you're right without a ported head, it's not necessary. I did it because I wanted to port everything. As long as you follow the rule of going from small to big you'll be fine.

 

[oldman]

BTW you did flip the paper after you cut it right?

 

[Chadillac2000]

either my paper cutting skills, or my fingers not working from extreme vibrations for like 5 hours of porting the last two days cant handle any more porting for a while, but thanks for guiding me through the process old man, and my last post will be in a couple days when I actually see if this cures my creep...

 

[Chadillac2000]

and yes i did flip the paper, i would go back and make it perfect, but right now i cant,

 

[oldman]

thanks for guiding me through the process old man

You're welcome. This one was fun and painless because you follow directions well and you do your own research. Good luck.

 

[Chadillac2000]

Just beause with no o2 housing on the flapper open parallel doesnt mean it will once you bolt the o2 housing back on. Just something for you to check out while you have everythign off.

Glad i checked this, all the clearance I had made by porting behind the flapper got closed back up when i mated it up to the o2 eliminator, so i had to do a little bit of porting to that too, to mirror everything that i had done to the wastegate side and so the door would open parallel, thanks 90blacktsiawd, and i rounded off my manifold so its more circular

 

[oldman]

damn dude your inlet porting puts mine to shame... I got bored after about 20 minutes and put it back together ... Almost makes me want to take it apart again.

You had your chances in the other thread, you're the only person I lost to the EXTERNAL side so far.

 

[Chadillac2000]

Oh yeah and i dont wanna resort to going to a machine shop to get these damned bolts out of the inlet, so far ive tried drilling, even with titanium bits wont budge, they just break or melt, then tried welding a nut to them and unscrewing it off, but even when its red hot it wont work, anybody got any ideas, this sucks

 

[LessIsMore]

I tried drilling out a broken bolt in a turbine housing once. Gave up after about 5 mintues of drilling and brought it to a machine shop. Cost me 20$ and only took 30 minutes, well worth avoiding the headache of doing myself.

 

[oldman]

Oh yeah and i dont wanna resort to going to a machine shop to get these damned bolts out of the inlet, so far ive tried drilling, even with titanium bits wont budge, they just break or melt, then tried welding a nut to them and unscrewing it off, but even when its red hot it wont work, anybody got any ideas, this sucks

Carbide and cobalt bits are both harder than titanium but I would just take it to a machine shop like LessIsMore suggested, turbo bolts are grade8 I believe.