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BudmannG
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! biggthumpup.gif
natedogg
Use a 2G exhaust manifold and a tubular O2 housing. You can weld the WG inlet to the O2 housing.
BudmannG
I don't think that will work nate. Here is a pic so you can see why.

natedogg
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
That was what I was concerned about. It being welded shut. Thanks for the help! biggthumpup.gif
The Iron Goat
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
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 wacko.gif ! But this is something I will have to explain to the person doing the welding. biggthumpup.gif
The Iron Goat
^^^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
That will work perfectly. Goat said it in a much clearer manner than I did.
BudmannG
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! laugh.gif

Thanks guys! I bow down to you!
BudmannG
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
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... unsure.gif
AWD DSM 1
If you're running an external wasegate, open that sucker up!
BudmannG
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
A&I supply has them in stock. A sleeve of four different burrs will run about $45.
BudmannG
Done! biggthumpup.gif



The Iron Goat
Looks good. Let us know when you get the thing together.
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