I recently picked up a 10th AE and it came with a hybrid S5 turbo. I just want to port the wastegate while i have some downtime being im sick as hell right now and cant do much anyways. My only issue is finding a carbide burr that will be long enough to get down into the holes. Any one have a part number or something. Preferably something that will fit a dremel or 1/4inch die grinder. I have the how-to from fc3spro.com to follow. I just dont want to have boost creep with my soon coming 3 inch turbo back exhaust and 3 inch TID setup

 

Is the hybrid a BNR?

 

I dont believe so. I know it is an S5 and inside the the outlet for the charge pipe it has .70 inscribed in it. The front of the turbo is polished also. The PO had bought it as a hybrid and gave it to me telling me it was. It was rebuilt and hasnt been used yet from what i can tell.

 

Try this place. You can purchase their burr grinders on-line. You can also d/l their catalog and price lists in PDF. They have burr grinders with regular length shanks as well as "extended shanks".
http://www.burrs4less.com/

 

One other thing. Is this something that require pin point precision? or as long as i go easy i should be ok? i just dont wanna ruin a freshly rebuild S5 "hybrid"

 

do you have a place like Fastenal or Grainger near you?

 

Well you want the flappers to seal after your done some some precision is required. If you want to go really big you will need to weld new flappers onto it.

 

Scribe or draw an outline of the door on metal. When you're boreing it out, keep at least 1-2 mm of metal along the edges, so it will still have something to seal against when you're done. If I remember right, I expanded the larger port by about 2 mm & the smaller one by about 5 mm.

 

Be sure to take out material along the runners as well. It does you no good to just open up the holes where the flappers seat.

For ease, separate the turbine housing from the center section.

 

Im pretty sure that's the same amount I did on my hybrid. About 1.5 mm smaller than the flapper for each port. Like this:

[IMG][/IMG]

 

Fastenal is the closest

 

Here's my tutorial on S4 wastegate porting:
http://www.aaroncake.net/rx-7/s4wastegate.htm

I know it's not quite the same, but the concepts are similar. If you have a die grinder then you can just use hardware store grinding stones like those pictured in my writeup. The high-nitrile cast of the turbine housing is quite easy to grind.

 

^^^^That's good info.