i had an idea tonight about converting my stock S5 actuator WG to an external WG. here's my idea...

- port heck outta wg
- wire stock wg open
- block off where wg dumps into dp
- cut a 2" hole and weld a pipe to the hot side were wg dumps
- make a flange for a external wg (HKS or Tial)
- mount the wg on that flange and run a custom dump tube

it makes sense in my head but i thought i'd bounce this around off you other guys.

if this has been done already or already thought of then sorry for the repost.

 

an easier way to conver it to an external but not the best, would be to weld the stock flapper shut, cut a hole in the stock manifold and weld a flange on. Reason its not the best idea is cast doesnt weld the best so dont know how long it would last, and dont know if you could hit both runners without a problem.


And just to let you know i did this with my awd tsi talon when i had it and it worked out fine and is still fine today.(My buddy bought the car)

 

It is almost impossible to weld cast. The heat will cause it to crack. My .02 from a welder. Greg C.

 

http://fc3spro.com/TECH/HOWTO/KWG/kwg.html

Anything else is waste of time.
We got an H-trim compressor uprade to hit 2.5psi maximum with this ported wastegate.
Even with a boost controller, we could only hit 12.5psi of boost, due to a slightly restrictive exhaust (2.5" pipes).
Porting the wastegate is a very economical option.
If you want to waste your money on an external, it's your money.


-Ted

 

Ted, i've already ported the WG once and i still had it spiking to 15psi in 2nd through 4th gear and i never tested it in 5th. i have a full 3" turbo back using the racing beat 3" DP, 2.5" inner diameter RB presilencer, and Apexi N1 single that goes from 3" at the presilencer to 3.5" at the canister. short of doing the external wg setup that BLUE TII has done, the only other option is to report the wg bigger. has anyone ever welded larger flappers on the S5 wg like they do with the S4's so you can "overport" it?

 

Actually, I've already made the flanges to do it on an S4 using 1/2" steel plate. I never got around to finishing it, but your idea is what I had in mind.

 

BLUE TII has also done this earlier this year using a 60mm HKS wg. thats where i got the final idea for it. if i was to make a new plate outta 1/4" steel then i could weld it up without any worry of cracking right? or am i totally off?

 

How big did you port it?
It sounds like you didn't port it correctly.


-Ted

 

i ported the exits more then anything. i didn't/couldn't get to the inner pathways since i was using a dremel. i think i should look into an electric die grinder like in the link you provided me. since i'll have the turbo off the car for the new short block i'll get a chance to report some more.

 

Yes, just enlarging the holes will not give you the best performance.
The flow potential increases a lot when you massages the inner passages.
I think once you start cutting into the inside paths, you'll get better wastegate performance.


-Ted

 

Dori Damage? Choku dori?

 

i'll definately try to get those inner passages larger when i get the turbo off the car. thanks Ted. i heard back from BLUE TII the other day and he said that his external conversion didn't help his spikes at all. so it looks like i'll scrap that idea.

 

I believe his problem was "fixed" when he dropped down to a 3" exhaust.
I think he was running a 3.5" or 4" exhaust system that induced the huge boost spikes that even his 60mm WG couldn't handle.


-Ted

 

wow, thats pretty damn big. i'm just running 3" like i said before. still, i'm going to re-read your site and get the wg paths ported better.

have you seen any problems with boost spikes after properly porting the S5 wg while running a full 3" exhaust?

 

No, almost zero boost spiking with 3" full exhaust.


-Ted

 

awesome, thats just what i wanted to hear. thanks alot Ted