TIIFC3S

I have the turbo off my S4 TII and was planning on porting the wastegate. But when I was taking off the plate in between the DP and turbo, both bolts snapped. Now with a little bit of work I know I'll be able to get those broken bolts out, but I'm worried about further disassembly of the turbo and more broken bolts. With the plate off, I can see the wastegate. Can I just port it now? Or do I have to take the turbo apart to do it safely? I'm just concerned about metal pieces getting into the turbo itself. The last thing I want is to take apart the turbo further and have 4 more snapped bolts.

Second porting question. I was also thinking of doing a minor port of the turbo inlet as outlined here:

http://www.fc3spro.com/TECH/HOWTO/TU...ORT/tport.html

There are some minor cracks forming around the edges and I'm concerned that if I start grinding it'll cause the cracks to get worse? Or will the grinding just remove the cracks all together as I'll be grinding there to expand the hole? What are your thoughts?

powrdby13B

It sounds like you're not really sure of your die grinding/dremeling skills - especially if you're unsure how to get all the metal filings out afterwards. So unless you have someone around who knows what they are doing, no you should not port anything. It won't crack any worse if done well but if you do it bad you'll catch your cutter on those cracks and tear the **** out of it!!

Soak the turbo in WD-40 and brake cleaner to get the bolts loosened, and try heating it up a bit to get it off.

Yes, anything on ted's site is fine to do to your car.

And most important, why are you putting a cracked turbo back on your car?????

Aaron Cake

iTrader: (1)

A small port isn't really going to do the job on an S4. You need to go all the way, to the point where you have to weld on a new flapper door:
http://www.aaroncake.net/rx-7/s4wastegate.htm

A few cracks around the wastegate orifice aren't a big deal really. You'll probably grind through most of them anyway.

Don't do this on the car. Remove the turbo using plenty of penetrating oil. You'll need to remove the bolts that snapped off otherwise you will have a constant exhaust leak.

TIIFC3S

I'm not at all concerned about my ability to use a dremel or remove bits of metal once completed. I've just never done this before and wanted to ask people with more experience than I what worked best for them. Between myself and my buddy, this is well within our technical abilities.

Referring to the cracks, there are no cracks around the wastegate hole at all. The cracks are where the turbo meets the manifold. I didn't think they were too bad, but they may be worse than I originally thought. The turbo has no other cracks or damage other than the ones you see in the pics. Is the turbo shot? Rather than porting it like Ted does, would it be safer to leave it as is?

Quick note, I'm only tearing down the engine to fix a few leaks, remove crap I don't need, and learn about the engine. As soon as I can save up some money, I plan on rebuilding the engine and doing a BNR stage 3 upgrade. So if the turbo works, I'm not overly concerned about the cracks at this point. I just want the car to run better til I can get it rebuilt.

sharingan 19

iTrader: (16)

As was mentioned earlier, if you're confident in your abilities it isn't gonna hurt anythign to port the exhaust housing, those cracks don't bode well for the long term, but porting won't make that outlook any better or worse.

I was in a similar situation a while back, I could port the w/g just fine but I couldn't weld on the neccesary flapper. I just picked up an S5 turbo/manifold and ported to the limit of the stock flapper(s). No welding, and "pre-ported" runners.