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how to port wastegate...

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Old 05-15-05, 11:08 PM
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Arrow how to port wastegate...

i need to port my wastegate. ive been told how to do it. (from what i get out of it) remove front turbo, paint wastegate flapper and area, and port painted area until the door barely seals. but i dont want to just hack into this. does anyone know of a video or good writeup with pics?...

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Old 05-15-05, 11:19 PM
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There really isn't anything to screw up as long as you put it back together correctly. Just don't overport and you'll be fine.

I used a die grinder and a carbide burr and it worked pretty well.
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Old 05-15-05, 11:42 PM
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port it to 1.24" its really simple, you just take the turbo off. once you get them off you take them apart (its 4 bolts to each side) and you port it. put it back together and your good to go. just trust yourself. you wont mess anything up
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Old 05-16-05, 03:09 PM
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so is it necessary to paint it?...
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Old 05-16-05, 03:42 PM
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It's not super necessary to paint it - you can typically see the area that the wastegate was sealing on. Also, the grinding typically is a slow process, so you'd REALLY have to get buck wild to overport the hole.

It's really much easier than it sounds. The hard part is getting the turbos off the car to do the work in the first place.

Dale
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Old 05-16-05, 05:12 PM
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Am in the middle of doing this myself. Got the turbos off and apart from each other but can not remove the turbine housing away from turbine. Have undone the clamps but no joy. Didnt want to do it together incase i never get all the grindings out.
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Old 05-16-05, 08:50 PM
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got the new turbo apart and its already ported so im now in the process of installing them...
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Old 05-16-05, 09:15 PM
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Originally Posted by z4csl428
got the new turbo apart and its already ported so im now in the process of installing them...
How long did it take you to port it?
It took me about 4h with a dremel, my back was locking on me by the time I was done...

BTW, I love the picture on your avatar... Did you create it yourself?
I had a same thing in my mind to do...
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Old 05-16-05, 09:27 PM
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If you use a good carbide bit and a die grinder, you can hog out a wastegate in like 10 minutes. But, of course, GETTING to the wastegate is the tricky part .

I've used some bit on a Dremel in the past before I got air tools that did the job pretty quickly. Can't remember what it was, though.

Dale
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Old 05-17-05, 03:56 PM
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You were going to try to port BNR stage 3s?
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Old 05-17-05, 04:01 PM
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yea i wasnt sure if they were ported. do they come with the wastegate ported from BNR?...
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Old 05-17-05, 07:51 PM
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That is something I would have checked before I took them apart.
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Old 05-17-05, 08:34 PM
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why? its not that big of a deal to take the front turbo off and look at the wastegate. why be lazy and take a chance on it not being ported and having to pull the turbo completely off again and porting it?...
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Old 09-15-05, 11:55 AM
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is it possible to port the wastegate WITHOUT taking the turbo's appart?? I have them out...but i want to know if i have to take the extrat mile and take em apart.... plus if i take them apart won't i have to replace some gaskets, seals, etc. etc.???
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Old 09-15-05, 12:00 PM
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no but its not hard at all to pull the front turbo off, like 6 bolts...and you dont have to replace any gaskets, etc...
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Old 09-15-05, 07:32 PM
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Originally Posted by WONG FRIED RICE
is it possible to port the wastegate WITHOUT taking the turbo's appart?? I have them out...but i want to know if i have to take the extrat mile and take em apart.... plus if i take them apart won't i have to replace some gaskets, seals, etc. etc.???
No! You must take the exhaust manifold apart, but you won't need any new gaskets or seals. Wastegeate is on the exh. man. so you don't need to deal with the turbo internals, but you'll need to protect them well from the metal shavings and debree, so they don't get in there.
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Old 09-15-05, 08:29 PM
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Originally Posted by TwinTurbo93
No! You must take the exhaust manifold apart, but you won't need any new gaskets or seals. Wastegeate is on the exh. man. so you don't need to deal with the turbo internals, but you'll need to protect them well from the metal shavings and debree, so they don't get in there.
u mean take the primary turbo apart? :P
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Old 09-15-05, 10:19 PM
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Originally Posted by WONG FRIED RICE
u mean take the primary turbo apart? :P
No!.
All you need is to do is, split the exhaust manifold, nothing to do with the actual turbo cartidges in this case. If you look or put your fingers from the DP hook-up port on the manifold, you can see/feel the wastegate port.

See this immage of the wastegate.



Also read this great how-to for further details, it covers almoast everything you need to know about porting and other stuff.

Good luck.


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File Type: bmp
wastegate_porting.bmp (88.9 KB, 6881 views)
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Old 09-15-05, 10:36 PM
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Originally Posted by FD3RotorTurbo
port it to 1.24"
That's diameter right?(just clarifying ) So if I brought it to a machine shop to get the whole hole ported equally... What would I have to take off? I already have my exhaust manifold off the car but I just want to make sure what I would have to remove if I got it ported by a machine shop.

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Old 09-15-05, 11:29 PM
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Originally Posted by jeremyb
That's diameter right?(just clarifying ) So if I brought it to a machine shop to get the whole hole ported equally... What would I have to take off? I already have my exhaust manifold off the car but I just want to make sure what I would have to remove if I got it ported by a machine shop.

Jeremy
Only the highlighet side of the manifold needs to be taken to a machin shop. You can even unclip the turbo cartidge of to avoid any possible damage,

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Old 09-16-05, 12:21 AM
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If you want to do it yourself and have access to a milling machine -
The way I did it was to completely take it apart, clamp that turbine housing on to a mill, indicate the flapper, and bore out the hole. I used a boring head, but only because I didn't have access to a CNC mill at the moment, which would have been ideal.

PS Twinturbo93 is right about only needing to split them apart and bring the assembly on one side. But if I were the machinist doing the job for you, I would definitely charge you extra because setting that up and indicating it (if it is to be milled) would be a bitch and take a lot of time.

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Old 09-16-05, 08:33 AM
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Originally Posted by DaleClark
If you use a good carbide bit and a die grinder, you can hog out a wastegate in like 10 minutes. But, of course, GETTING to the wastegate is the tricky part .

I've used some bit on a Dremel in the past before I got air tools that did the job pretty quickly. Can't remember what it was, though.

Dale
Hey Dale,
Been PM'ng you on that tach you were interested in but no reply. Jack
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Old 09-16-05, 08:51 AM
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I own a machine shop, would any of you guys be interested in having me do a bunch of these. I would need you cores, But not shure If I would whant to disassemble your turbos. So you would have to do that, this would also cut down on shipping. If I were to get maybe 10 I think it might be werth my time. Not shure on the cost but I will be doing mine in a couple of weeks (maybe sooner). I could make a fixture and a program for the CNC.

Anways just throwing it out there.
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Old 09-16-05, 12:25 PM
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^would have to know some kind of price and a return time as my fd is my daily driver.
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Old 09-16-05, 01:31 PM
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Not to shure on return time as that would depend on the shiping. I guess with next day air or local drop off and pick up shouldn't take more than say half a week. This could be different on a individuale basses.

The actual set up and machining once the fixture and program are done shouldn't take more than about 15 minutes, That would include prepping the suface were the fixture is atached, loading and removing the peice from the CNC, and miner adjustments for iregularites in each peice. I could also include sand blasting or bead blasting at a aditional charge.

Shop rate can be any were from $50 an hour to $75 an hour. I would also have to cover shipping back to you.

If I could get a bunch at a time the price could be much better. On a individual bassesI would think about $35 should cover it. Assuming that this peice doesnt weigh too much.

Feed back on this would be great. I am running a group buy for somthing else on this forum if any one whants to see how I handle things.

Thanks for the interest
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