Extremely loose exhaust sleeve
 

I’m getting ready to rebuild my s5 NA and I’ve got it torn down to just the block. Still waiting on some time to fully tear down the block but want to see if I can get some insight on this before I do.

From the looks of it, whoever rebuilt this motor last swapped the exhaust sleeves from the NA to turbo to remove the baffling, however to do this instead of drilling or pulling the roll pins, they used what looks like a dremel cutting wheel to cut the pins off. I can get pictures tomorrow night so you can see what I’m saying, forgot to get some before leaving.

Now both have cuts into the housing down to the pin, which look liked they would be sealed fine by the gasket, and the rear sleeve is properly locked into place. However the front sleeve has ALOT of play in it. I can move it in all directions as well as rotate it about 15 degrees each way. It cannot be pulled out farther than maybe an 1/8 of an inch. From what I can tell from the outside, it has both pins but the holes looked to be wollered out. If I push it back to where it would be with the exhaust on, it does like up well with the exhaust port.

My question is, if I can’t get it to set right after pulling it all apart what are my options? Can I JB weld some new pins into the holes or am I just SOL and need a new housing?

If a new housing is needed, can a rear housing be used in place of the front? I do not have any emissions on the car or need to pass a smog test and as far as I can tell that would be the only issue.

Would I get any benefit or have any issues out of swapping to T2 housings. More than likely I will replace both housings in the event I can’t make this front sleeve work

i wouldn't be comfortable with a sleeve that can move that much. you might install the manifold and see if it doesn't clamp the thing down.
you're going to need something metal to hold it in, although i'm not sure you'd need anything super fancy

You can remove the roll pins and replace them with a set screw.