So I took apart my stock turbos to port the wastegate and I noticed that the gasket that comes between the primary turbo and the manifold is cracked...

so I took apart the secondary turbo to check that gasket and it was also cracked (i'm not talking about the gaskets that come in between the turbos and the exhaust manifold)



Here is a pic of what gaskets I'm referring to...



I searched online and could not find replacement gaskets...anywhere

So I found a guy back home who makes replacement gaskets and he did a great job of making new ones. I told him that they are turbo exhaust gaskets and need to withstand insane amounts of EGT. He assured me that the gaskets will outlast the turbos...not sure about that though...

so here they are...





So what do you guys think, will these gaskets be ok? I heard bad things about graphite based gaskets, and I'm not sure what material these are made of?

If these are not safe to use, what would be my options? Any ideas where I could get good replacements?

 

Are the stock gaskets inconel? Or some kinda stainless?

I tried some good used stock 12A gaskets on an S5 turbo install between the turbo and engine and they lasted more or less for about 200 miles. I saw evidence of leakage so I swapped in some new ones last time I had the turbo off a couple days ago.

The new ones smell kinda weird! I'm sure they're "breaking in". I'll test how much they've gotten crushed or flattened due to heat cycles after a while and tighten up the nuts if necessary. I just want something that will hold up for a while, but I've got some FD gaskets somewhere around here I can swap in if necessary.

I'm sure your custom made gaskets will crush after a while and could leak. That gasket style isn't really geared for insane EGTs.

 

I'm not exactly sure what material the stock ones are, but they are made up of multiple thin metal sheet layers. If that means anything...

The turbos I got are low mileage, have no cracks and no shaft play. Only bad thing is the cracked stock gaskets. It would be a shame to install such good condition turbos with bad gaskets...

 

I would surface all the pieces flat carefully and put it together without a gasket before I would try those aftermarket gaskets.

Stock S4 and S5 turbos don't use any gaskets between the turbo and backplate and have worse material thickness and bolt spacing for even clamping forces.

You could also try calling BNR to see if has some used spares from turbos that came through and didn't get rebuilt because of cracking, etc.

 

Hey Blue TII, The surfaces have been flattened down. One issue that I think may come up is that if I dont use the gaskets the turbos (once assembled) might not alling with the exhaust manifold. What I mean is that the holes for the bolts may not allignt. The whole assembly will be 1-2 milimeters shorter (closer together)

Good idea about contacting BNR, I'll do that first thing tomorrow.

 

OP Did you call Ray at Malloy Mazda to see if they are available? He would be the best place to ask.

 

I had the same issue but did not find any replacement for those. Looking forward to know how these perform or if there is any possibility of getting some spares anywhere.

 

I thought about that, but after searching a ton online could not find any info on said gaskets. Even the hitachi rebuild kits do not include them. I guess I could call Ray, but I doubt he would have them. I assume the Mazda service would not ever take the turbos apart, but rather just replace the whole unit...

 

As Blue TII said, BNR is probably a good place to find replacments, if they would be willing to sell them...

 

I don't think the gaskets you made are going to last. I've tried using something similar years ago and they lasted a few hundred miles before failing. If Ray Crowe cannot get them, I would find some out of a bad set of twins. Personally I don't think its worth putting a lot of money and time into the twins. I probably have something used laying around the shop as well.

 

Thanks for the info! I will not be using the gaskets I made.

Andre the Giant read my thread and sent me a PM. He has a set of used ones that are not cracked and will be sending them my way. What a cool dude

And I agree that puting money into the twins is not worth it. However I got this extra set of twins for cheap, and they are in great condition. And for now I'm ok with having the twins. Don't have the cash now to go single. Maybe one day.

 

graphite gasketing material can generally withstand the most heat

edit; I don't think those replacement ones are graphite. That looks like the same stuff exhaust flange gaskets are made from.
Graphite gaskets look like this. It can take a lot of heat, and is very good with steam, but is not that durable.

 

Yeah that's the first thing that I thought when I saw them...exhaust flange gaskets. Which is ok for that...but using them in the actual turbos with the huge EGT...probably not so good.

I was under the impression that graphite base gaskets are not so great...

 

Have you tried ordering from Mazda? Call up Ray Crowe at 703 490 5296.

Based on the look of them in that last picture you posted, there is no way in hell they'll last at all for the given application. Between the down pipe and mid pipe maybe. Further upstream? no way.

Your exhaust gasket guy isn't doing you a favor assuring you they'll work fine. That's a lot of work in the event that he's wrong.

Also, i'll bet they're too thick, which may cause misalignment issues for you with water lines and your exhaust inlet, not to mention the y-pipe.

 

Hey Goodfella, you are right, they are too thick. I put them on and assembled the turbos and the bolts do not align with the exhaust manifold. That's why I was looking for an alternative.

I just received the gaskets I need from Andre the Giant and they are in great condition. Compared to mine they look like new. So I'm good now.