Im going to be porting my wastegate soon, and i was wondering if there was anything special i need to know?
I read all the stuff about turbo removal, but with porting the wastegate, is there anything i should know b4 i tackle the task?
all info is welcomed
thanks

 

S4(87-88);
http://fc3spro.com/TECH/HOWTO/ZWG/zwg.html

S5 (89-91);
http://fc3spro.com/TECH/HOWTO/KWG/kwg.html

 

One thing you should do, weld on a new flapper and then port. Porting to the size of the stock flapper will help but still will not flow enough for an open exhaust and intake.

 

where can i get a bigger flap?
im not very good at welding... does it have to be perfect?
(my dad is pretty good, but still no professional)
thanks

 

also, is it better to go with an external wastegate?
if so, where can i get one for fairly inexpensive?
will it be extremely loud, or will you not really be able to hear too much of a difference?

 

the weld must be good and strong. done properly as it will be under some pretty harsh conditions! Extreme Heat and all.
You can do an external WG, Will give you more control of boost, however it is difficult to do and again requires custom welding.

 

Also be careful of the bushing on the WG.

I think when I ported mine I bent the flapper rod a bit which made it have a small spot stay up and open. This would have created a boost leak,

BTW Series 5 hotsides are impossible to find!

If you have the hotside off check for cracks.