Wastegate Solution for HKS Manifold Users
11-11-09, 03:26 PM
#1
Wastegate Solution for HKS Manifold Users
The adapter kits are available on our site, but I am specifically trying to avoid this becoming a "For Sale" thread. This is a technical product notification. However if the mods feel it is located in the wrong section, I am sure they will let us know. 
As most people are aware the HKS 50mm wastegate with the standard mating flange was discontinued years ago. This left only the HKS 38mm as a direct bolt on for manifolds using this flange design. This has created a lot of problems for HKS manifold users.
We have found that the HKS 38mm wastegate is inadequate when used in conjunction with ball bearing turbos (GT35R, T04Z, etc), resulting in uncontrollable boost creep. Our solution is the installation of a TiAL 44mm wastegate, which eliminates this problem. To accomplish this we designed an adapter. We have been making these for years and have tested it on many different cars/turbo setups.
Our adapter utilizes a laser cut .375" mild steel manifold mating flange joined by 1.875" SS tube to an authentic TiAL SS V-band flange to guarantee a perfect fit with your TiAL 44mm wastegate. The assembly is Tig welded.
Here are pics:
Wastegate installed:
Bell housing clearance:
As most people are aware the HKS 50mm wastegate with the standard mating flange was discontinued years ago. This left only the HKS 38mm as a direct bolt on for manifolds using this flange design. This has created a lot of problems for HKS manifold users.
We have found that the HKS 38mm wastegate is inadequate when used in conjunction with ball bearing turbos (GT35R, T04Z, etc), resulting in uncontrollable boost creep. Our solution is the installation of a TiAL 44mm wastegate, which eliminates this problem. To accomplish this we designed an adapter. We have been making these for years and have tested it on many different cars/turbo setups.
Our adapter utilizes a laser cut .375" mild steel manifold mating flange joined by 1.875" SS tube to an authentic TiAL SS V-band flange to guarantee a perfect fit with your TiAL 44mm wastegate. The assembly is Tig welded.
Here are pics:
Wastegate installed:
Bell housing clearance:
11-12-09, 03:31 PM
#7
Great question!! I didn't even think of it until you asked. Now that the Auto trans guys can run the PFC with our EMS adapter, I really need to keep this in mind when developing new products. There is plenty of clearance here is a pic with the auto bellhousing:
Another good question. The FC HKS manifold provides tons of room, far more then the FD. Here are pics of the FC manifold with the 38mm wastegate, the TiAL 44 does not take up any more room:
Thanks for the positive input. The adapter also works on the "other" makes of manifolds that utilize the standard HKS flange.
Thanks for the positive input. The adapter also works on the "other" makes of manifolds that utilize the standard HKS flange.
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11-12-09, 06:53 PM
#9
^^ I used to have the small HKS wastegate on my old FC HKS manifold. I remember there was no room to fit an ebay HKS 50mm knockoff in there without hitting the 3" custom downpipe I had, but that thing was huge. Do you think the Tial 44 would hit the downpipe if the downpipe came close to the firewall? Is the Tial 44 much longer than the HKS 38/40mm?
11-13-09, 11:52 AM
#10
It goes without saying that DP configuration effects the WG clearance. We have seen some pretty dreadful DPs. There is no way for me to tell you if the TiAL 44 is going to fit in your current setup, as I have never seen it. However, it is reasonable to believe that if the 38mm fit, then you should have no problems with the 44mm.
The TiAL technical drawing will help you: http://www.tialmedia.com/documents/w3_tial_44_dim.pdf
For people putting a new system together there should be no problems.
The TiAL technical drawing will help you: http://www.tialmedia.com/documents/w3_tial_44_dim.pdf
For people putting a new system together there should be no problems.
11-16-09, 09:15 PM
#13
No. We run the TiAL 60 on our 20B. If you are playing with turbos that require this wastegate, you will not be using the HKS cast manifold. The outlet of the manifold can't be open up enough to even make use of a 60mm WG.
11-16-09, 09:23 PM
#14
I do not believe that the Synapse shares the same mating flange as the Tial.
No. We run the TiAL 60 on our 20B. If you are playing with turbos that require this wastegate, you will not be using the HKS cast manifold. The outlet of the manifold can't be open up enough to even make use of a 60mm WG.
No. We run the TiAL 60 on our 20B. If you are playing with turbos that require this wastegate, you will not be using the HKS cast manifold. The outlet of the manifold can't be open up enough to even make use of a 60mm WG.
I know the TiAl 44mm wg, and the Synapse 50mm use the same wastegate flange, I guss what I would be asking is clearance wise if there is an extra inch (height wise of the wg) in the engine bay with the hks manifold.
11-16-09, 09:29 PM
#15
I do not believe that the Synapse shares the same mating flange as the Tial.
No. We run the TiAL 60 on our 20B. If you are playing with turbos that require this wastegate, you will not be using the HKS cast manifold. The outlet of the manifold can't be open up enough to even make use of a 60mm WG.
No. We run the TiAL 60 on our 20B. If you are playing with turbos that require this wastegate, you will not be using the HKS cast manifold. The outlet of the manifold can't be open up enough to even make use of a 60mm WG.
11-16-09, 10:25 PM
#16
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I don't think the wastegate would be the restriction in his setup, even with a transition pipe the restriction would be there. That's a big turbo for a cast mani!
11-17-09, 06:00 AM
#17
It would actually be for a friend of mine who has an hks and a 60mm tial he is fabing up to fit on it. The turbo he is using is a precision billet 76mm turbo which should work just fine on that manifold however I could tell from your pics that the tial 44 is about as big as it will get without going to some sort of transitioning of piping size... I'll have to let him know.
11-17-09, 07:39 AM
#19
We designed this adapter for the TiAL 44, not the Synapse. We cannot say that any other wastegate will fit without clearance issues. I see on the Synapse website they claim it is a direct bolt on, but I can not find any dimensional data for the unit.
I do not know which 76mm Precision you are talking about, but if it is the Gt42, I think your friend is going to have issues with the compressor housing hitting the LIM.
I do not know which 76mm Precision you are talking about, but if it is the Gt42, I think your friend is going to have issues with the compressor housing hitting the LIM.
Either way that's a cool piece. If I ever upgrade from my 40mm TiAl I'll get this.
Last edited by hondahater; 11-17-09 at 07:41 AM.
