I decided to make my own gaskets for my apexi turbo. keep in mind i have the old version of the turbo and that is what the templates are based off of. Also, I used copper as the material but that does not mean its an ideal material to use. Use the templates and this info at ur own risk, as usual I am not liable for anything, anywhere, and anytime :-)

Here is a pic of the template sheet i made and the resulting gaskets made from the templates. I did NOt have to make a new turbo exhaust outlet (circle one) however I created a template for it anyway for future use or incase someone else needs to make one.



I also decided to use better connection hardware and moved to allen bolts instead of the studs/nuts combination, so I took out the studs and sleaned up the threads, notice the size and thread 8mm x 1.25:


here are some tools/materials you will need:


some copper sheet material (or whatever you want to use), not too thick but not so thin that it cant compress a bit to make a good seal, a cutting wheel, a grinder bit, a drill and a drill bit to make the bolt holes in teh gaskets, and finaly tin snips to cut the copper sheet into shape.

pic of the wastegate gasket being sized up:


pic of the turbo inlet gasket being sized up:


To make the inside holes of the gaskets:
- on the wastegate gasket i used one of those big circle cuttign drill bits

- on the turbo inlet gasket i used the cuttign wheel on the dril to cut the basic lines, then poped the middle out and used the grinder bit on the drill to shep the inside better.

If you want to to mode to allen bolts you want this hardware:


- 8mmx30mm (1.25 thread) cap screw socket (allen bolt)
need 7 of these, 4 for the inlet, 3 for the outlet, you may be able to go shorter than 30mm length for the 4 inlet allen bolts, I havnt checked yet

- 1.25 thread nuts
need 4 of these for the ends of the inlet allen bolts (the other 3 allen bolts on the outlet side go into the turbo housing and dont need nuts)

- grade 8 lock washers, 5/6" will work
get a bunch of these and put them where ever you think you need to have them, i am going to use them on every bolt.

- 6mmx20mm cap screw socket (allen bolt)
need 4 of these, i didnt check thread on these so make sure you match what was there before

- grade 8 lock washers, 1/4" will work
get a bunch of these and put them where ever you think you need to have them, i am going to use them on every bolt.


and thats about it, so here is what you been waitin for, the pdf template file:

http://www.myrx7.com/images/apexi_tu..._damian_v1.pdf

 

nice

 

Nice work!

The only thing I'd worry about is the cap socket fasteners.
Most exhaust fasteners (i.e. stock ones) are Inconel or high nickel content that are made for high heat applications.
Those cap socket fasteners might be 10.9, but it doesn't mean it's designed for high heat.
I have 10.9 cap socket fasteners on my brakes, and they rust like a ****!



-Ted

 

I did the same thing for my 12a sigma turbo kits. Can't find gaskets for it. But the copper work nice. Good write up.

 

and the DIY award goes to you sir

 

thanks :-)

 

yeah, its best to get grade 8 or ss but ill be changin it all out after the track season so it didnt make a difference to me right now.

 

:-)

 

Damian is the KING of DIY. He does some marvelous work on his cars!

 

thanks, dunno about marvelous, but i try :-)

 

i like the screw idea. freaking bolts are kicking my ***. i will def try that next time i rip the car apart

 

screw idea? im not using screws (hehehe) did you mean allen bolts?

the reason i switched was because it much easier to get a allen tool in those tight spots and allen heads are not as easy to strip as traditional bolt heads or nuts.

and they look cool :-)

 

How are the gaskets holding up? ANd what type of thickness did you use? ALso is there different kinds of copper?

 

well, they held up well for a few events, but then i foudn aplace that had the gaskets and picked up a few so im set with real gaskets now :-)

ofcource now the kit is for sale since i have the r85 kit going on the car.