holes don't line up
 

so, i get this turbo kit from jason at rx7store, opted to get the kit without the warrantied manifold since it was $300 cheaper...never thought i'd get an ebayer xs power mani though. not from jason.

so...i line up the turbo and the flange and see that there is a one tap that isn't lined up with one of the holes on the turbine inlet...wtf? then i put some studs in the the flange and they are all pointing away from each other...meaning that the flange was warped. contacted jason via email and he admitted that the holes did not line up and must use the nuts and bolts supplied with the kit.

so my questions are: is it safe to use smaller bolts (assuming smaller since it would be logical that a smaller bolt will fit through 2 holes that are not aligned)to hold that turbo to the manifold IF the bolt was straight? would the turbo vibrate off? or should i chop it off and weld on a new flange? or...see if i can get the holes welded shut and retap them...

just grind the hole out on the turbine housing a bit so they fit, or try to straighten out the flange a bit. definately go over it with a belt sander at the very least.

If you have to use smaller bolts then just make sure that they are a heavy grade and can take the heat. Also make sure that there is a good seal between the turbo and manifold. I wouldnt recommend stainless steel it changes structure at that kind of heat and will break. Hope it works for you.

There's a big difference between a warranty and getting a part that doesn't work straight out of the box. Give rx7store a call and chances are they'll make it right with you.