i got some pretty agressive bits from work today thinkin this would be a breeze. well its not difficult just time consuming. my question is for my n/a turbo project should i port till the edge of flapper or do the washer trick? has anyone had sucess with just going to edge of flapper or should i keep going?( its a s4 turbo)

 

It doesn't take much time to port with a die grinder and grinding stone. With somethine like a wussy Dremel, it could take quite a while.

Since boost control is very important, port the orifice much larger then the flapper and weld on a washer. This is covered in the Archives, and the latest RXTuner magazine.

 

well im using a drill with the bit so i guess ill be here a while, thanks aaron cake.

 

just dump your hot side at the nearest machine shop with the size of the hole

70$ isn't really expensive for a clean and professional job. they also weld and ground a washer

look, it makes quite a clean job!



I also had them port my smallest runner

 

looks nice TII'87 i'm porting my wastegate right now on my s5 t2 i started to use a dremel and a carbide bur from lowes now i am using a 1 speed electric drill with a carbide bur im almost done just have to make them alittle bigger yet and smooth them down also i got a question of my own is it worth porting the exhaust runners or isn't it i wouldn't think it would make any diufference unless you port the exhaust manifold to

 

damn!!! thats beautiful!! now i look at mine and anwt to throw it in the garbage.^^^ good question do we need to match the manifold? is that the size of the gasket?

 

That will take weeks. Beg or borrow a Dremel or electric die grinder. Trust me.

 

it will take awhile like aaron cake said with the electric drill it's taking me awhile i keep stoping and do alittle bit because my arms get tired from pressing the drill against the walls and all

 

im sure you know its bad to put lateral force on the drill....now with that said i do it all the time myself.

and yes porting with anything other then a die grinder is a bitch

 

Milling machine.

 

^ looks nice did you do that or did someone else do it on the machine?

 

A friend of mine is a welder, one of his co-workers is a machinist... gave him 20 bucks for the machine work and my friend did the welding for free.

 

well im gettin somewhere. slow and steady,lol i plan on porting about as much as impulsive-rx7 but my q is when i go to put the washer on do i tac it while the flapper is down and washer flat against the hole insure proper sealing? should i weld it up good or a couple of penetrating tacs be fine?

 

Tack it while the flapper is closed if you can. If you can't, then scribe the location of the original flapper on the new flapper, raise it up out of the housing, clamp it on, then weld. Just run a bead along as much of the old flapper as you can manage. Should only take a minute longer then putting down several spot welds.

 

so should i port the exhaust and manifold also? again, any benefits? is it worth it?

 

i woudnt worry about the exhaust ports because it will be hard to port match them

 

Might as well port the turbo runners while you are there. Presumably you are eliminating the twin scroll, so you should port out the smaller runner to the same size as the larger one.

 

twin scroll will be gone seems how high comp. rotors are used and prob. wouldnt fit i assume, highly thinkin about takin it to machine shop for that though since ill never get this done within the end of summer.( should be when project is finished).

 

Probably cost about the same as just buying the proper grinder and bits. I now see cheap knock-off electric die grinders for under $50 (I paid close to $300 for mine), and a set of bits is about $5 at the hardware store.

 

thanks aaron cake

yeah i know its alot of basic q's but nobody around here has done this before and is clueless when i ask q's like this so you guys are my only option plus i dont wanna put all this work into it and have it blow or somthin leek within a week.