I was trying to figure out how to get the goddamn flapper out of the manifold for the twin scroll. I searched and read quite a few posts about people cutting it out with a plasma cutter. I figured that there was a way for mazda to get it in, so there must be a way out. It was easy.

The flapper has a shaft that connects to the arm wich then connects to the diaphram that moves this flapper. Between the arm and the flapper, the shaft that is, there is a 'bushing' that holds it in place.

Take a hammer and wack on the control arm until it twists off. Now you should see the shaft that once connected to the arm. Around this shaft is the bushing, wich has a single weld on the manifold to keep it in place. Take a flathead screw driver, with the nice big plastic yellow handle, and a hammer. You can chisel the bushing with the weld off very very easily doing this. Once the weld is broken off, take the hammer and screwdriver and push the bushing out of the manifold from the inside, where the flapper is. Once its out quite a bit, take some pleyers and pull it out. Now there is enoughe play for the flapper to come right out with the shaft.

 

i tried this and i didnt get it to work very well for me. i was trying to keep everything intact.. but i decided to die grind it out . i had my whole removal of the twin scroll done in about 5 minutes and that includes tapping and plugging the whole

 

I should have mentioned that this is if you want to get rid of it permanantly, and not keep the pieces. Im going to upload a couple pics to show you guys what im talking about, words arent clear enoughe..

 

i thought about removing it completely but there is still some benefits to the system, if i were to remove it it would only be because of an upgrade to a S5 turbo.

 

Yea I read that too when I searched, this is the turbos sort of equivelant of the 6 port system for the na. The flap stays closed by a diaphram that is held open by vacuum on a low rpm. When the rpms increase, the flap opens up. Having the flap open spools the turbo quicker for low end power. Its a really really smart idea.

I didn't want to get it to work with my NA conversion, so Im just removing it. THe compression ratio of my rotors should make up for the low end lost by removing this anyways.. at least I hope.

 

well with my porting i kind of need the added bit of low end power so i opted to keep it in case i didn't like the end results.

 

i just cut mine off today with a air powered cutting wheel

next i'll be porting the S4 little oval thingy so that both are the same size, then a little wastegate porting, and back on the engine it goes...

 

oval thingy?

 

Hey, the airpowered cutting wheel cut right through it. Then to fill the hole, we tapped it and drove a bolt covered in exhaust gasket maker through it. I applied roughly 280ft/lbs of force to apply the bolt, just for the fun of it.

 

I swear I've posted "hit it with a hammer" several times before.

 

Does the screwdriver HAVE to be Yellow? I only like red handled ones....


















Hey it had to be said!