BudmannG
May 8 2006, 06:20 PM
Here is my question. I have an external 40 mm wastegate that I bought and need to install. I have two choices to go with here as in exhaust types.
1. is tubular exhaust manifold and a tubular o2 housing.
2. is 2g ehaust manifold and 2g o2 housing.
The first choice would be easier to weld to. But I also know that they break easily with the weight of it all.
The second choice I have heard different things about. Like it is hard to weld to, or should I say vertually impossible for a good weld.
I would like all the input I can get on this. Thanks guys in advance!
natedogg
May 9 2006, 06:25 AM
Use a 2G exhaust manifold and a tubular O2 housing. You can weld the WG inlet to the O2 housing.
BudmannG
May 9 2006, 09:33 AM
I don't think that will work nate. Here is a pic so you can see why.
natedogg
May 9 2006, 09:44 AM
I'm not catching you. If you have a tubular O2 housing that bolts directly to your turbine housing there is no reason you can't cut a hole in it and weld on a flange for the external wastegate. If you are concerned about the internal WG hole just get a tubular housing the blocks it off. Looks like its already welded shut though.
BudmannG
May 9 2006, 09:49 AM
That was what I was concerned about. It being welded shut. Thanks for the help!
The Iron Goat
May 9 2006, 08:50 PM
I don't understand why that's stopping you. Drill out the wastegate in the turbo, weld a separator in the tubular o2 housing to prevent cross-over, bada-bing, you're there. Or is there something that I'm missing?
BudmannG
May 9 2006, 09:20 PM
My tubular o2 housing has an open dump setup on it.
So what goat is saying I can drill the old wastegate out. Then attach/weld the wastegate to the open dump part of the o2 housing. Is this correct?
Sorry if I sound retarded

! But this is something I will have to explain to the person doing the welding.
The Iron Goat
May 10 2006, 11:46 AM
^^^Yes, that's what I'm saying, and it should work so long as you can get that stock wastegate removed and cleaned up. At least, I see it as a viable option, though others may have a deeper understanding of the task at hand.
natedogg
May 10 2006, 12:03 PM
That will work perfectly. Goat said it in a much clearer manner than I did.
BudmannG
May 10 2006, 01:47 PM
Man I don't know what they used to weld it shut. But I have been working on it for the last two hours. It is acting like a woman!

Thanks guys! I bow down to you!
BudmannG
May 10 2006, 04:50 PM
I would like to know if I can port the wastegate opening bigger? I have a pick of how it turned out. This is after I got the old wastegate flapper out. I honestly don't know.
99Spyder
May 10 2006, 07:51 PM
Seems to me that porting the WG opening would help reduce the risk of boost creep and would not impact performance. Let's see if anyone disagrees...
AWD DSM 1
May 10 2006, 08:02 PM
If you're running an external wasegate, open that sucker up!
BudmannG
May 10 2006, 09:32 PM
That is what I was looking for! Woo Hoo! I am going to reem it tomorrow. I still have to finish the exhaust manifold. But it is going great. I also have to get new carbide burr bits. Those things are like hunting for a needle in a hay stack.
The Iron Goat
May 11 2006, 12:41 PM
A&I supply has them in stock. A sleeve of four different burrs will run about $45.
BudmannG
May 11 2006, 02:31 PM
The Iron Goat
May 11 2006, 02:42 PM
Looks good. Let us know when you get the thing together.
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