I figured it was time to port my wastegate, since the full 3' exhaust, 3' TID, FCD, and my beloved boost might appreciate it and raise a little!
Hopefully these pics will work.

I know i probably could have hogged out a little more, but i was being cautious. If i still have boost creep, i'll pull it again, and port more. But i think it should be fine now. Wha do you guys think?

 

Nice!
So what tools did you use?

I will be doing this to my new hotside soon and lsat time I did it I used a dremil and it took FOREVER

 

you didn't use a larger flapper correct?

 

i did the same porting (infact that looks almost identical to mine) and it did almost nothing to help my boost creep. the problem is the 90 DEGREE TURN that the wastegate exhaust has to take before it gets out into the downpipe. also, the freakin flapper door doesnt even open all the way! horrible horrible design IMO.

 

Air Die-grinder with a few different bits... wasn't too bad for my first time at it.
Although there were a few cracks here and there i wasn't too impressed about. But if it goes, then it goes,.. and its upgrade time.
Yeah, i tried a dremel for a little bit today,.. it was awful, if anything, it just smoothed out a few ridges, but i would never port the entire thing with it. Its the stock flapper, but i did trim just a little bit off the top where it hits the backing plate... also did trim down a divet on the backing plate for more room.

I totally agree with you on the horrible design,.. but sometimes you gotta work with what ya got. So, i'll see how this holds up.
The thought of a divorced wastegate with dump tube or even turning it into an external wastegate came across my mind, but thats too much work for a stock turbo, and welding cast iron? Good luck!..but still seems like a waste on something thats probably going to get upgraded or replaced.

 

You need to radically increase port size, beyond the stock flapper door. Then weld on a new flapper. In my opinion, that's the only time porting the wastegate is worthwhile.

FWIW, this wastegate design is used by 99% of stock turbos. When properly sized (unlike our cars) it works very well.

 

Even with the S5 manifold Aaron? i know with the S4's it seems to be crucial to port it much larger then the stock flapper door, with a weld on washer and such.

But in the case of the S5,.. should the same be warrented?

 

what would you use for larger flappers on an s5?

 

same idea as S4 but 2x .. washers, piston engine valves cut to size, etc.

 

if you wanted to couldn't you make the two holes just one big oblonged one and make a piece of metal to fit and weld it on? or are they two seperate chambers? Sorry for my ignorance, I've never seen an s5 turbo in person.

 

They are divided.. each one forming its own runner.
I would think porting the wall between would compromise the structure. And would probably result in cracks or worse failure.

 

why was my post deleted?

 

ah thanks for the explination.

 

Another issue is where the flapper door hits the back plate.
Opening the door wider will make a big flow increase.
The yellow line in the picture shows where the door hits the back plate.




I back cut the door with a mill file.
It was easier to control than a grinder.

 

very nice info and pics sureshot. so how did all that work out for you? it looks like you did a good job

 

There are no deleted posts in this thread.

 

anyone with the same porting as myself/ Sureshot/ jacob ?
How did it turn out for you? successful? Wasn't enough?
Feedback would be helpful.