Installing A External Wastegate

[zayd687]

hi guys

whats involved in installing a wastegate? I've read on the net, you can either put it on the dump pipe or manifold.

have any of you guys put on an external yourself?

im wanting to attempt to put an external on my car, but im not sure how to run the lines or if its a quite a big job.

[ms700]

You will have to block up your internal wastegate first, im guessing you are still running the standard turbo?

Then weld on a pipe to the manifold to accept the new external gate. And then replumb the gate into your exhaust system, unless you want to run a screamer pipe.

Umm, why are you keen for a external gate?

[zayd687]

thanks for the reply,

yeah well 've got a garrett gt35r or sumfin my mates given me for bugger all , its in quite a good nick.

it had an internal wastegate yet, where its positioned couldnt meet the clearance below the manifold as there was a plate

that hits the actuator rod and stop it from being installed.. I changed the actuator rod but to no luck the flap is open now

all the time not being able to hold boost.

so the only option I have which I think is favorable is welding the flapper closed and removing the actuator out from the housing.

install it.

then purchase a tial 35-38mm? .. so I make a hole in the manifold, how big does the hole have to be? I can drill it and bore it... but does it

have to be exactly 38mm?

also have you guys had any trouble welding steel onto cast iron? was there a particular coil you guys used when welding?

sounds like an interesting job, after you weld the pipe.. weld the flange on the other end of the pipe and run another pipe plumbed back into your exhaust?

so that means cut another hole in the dump pipe?

where the hell am I going to find such small piping?

it would need bends?

sorry for the questions

just never done this before so first attempt

Edited 26/12/10 01:03 AM by zayd687

[dalts]

hi mate

id be asking kyle from 6boost,he is the expert in that area!!

cheers lee

[RAP1D]

Your kind of on the right path mate.

I'm assuming your ok with fabrication at this level, if not get a pro onto... Leaks in the welds will drive you nuts if you don't get it all done spot on.

But yeah, the wgate has to come off the manifold ( or exhaust housing ), usual a 45 or 50mm gate is the minimum size, 38 is usually too small, then it needs to plumb back into the exhaust just befor the cat.

You'll needs pipe bends, flanges , gaskets ect ect

a well set up external gate will give awesome boost control, good luck with it.

[PSI40L]

Rapid chris yours is done like this isnt it maybe u can give us some pics for ideas

[RAP1D]

Yeah mine is mounted off the turbine housing... This isn't for everyone though, breaking out the 2 inch hole saw and cutting into an expensive turbine housing takes a bit if know how, plus it's a twin scroll housing so took alot of die grinding to get it all smooth inside, especially the divider.

A simple steam pipe bend welded to the housing then a length of stainless pipe, a couple of slight bends, mounts the wastegate next to the sump, then more stainless bends of very slight angles and into the dump just befor the cat.

I'll look for some pics when I'm back, also done this on a few BAs as budget systems which worked very well.

[freeze_dk]

mounted off the exhaust housing looks awesome

[kartman]

The size or effectivness of a particular size of wastegate is dictated by the positioning of the wastegate, on top of the manifold usually isn't the best as the exhust gas has to redirect 90 degrees to exit the gate, where ever possible the gate should be in the direction of exhasut gas flow as it will be most efficient, hard on a cast factory manifold and often poorly done on aftermarket tubular manifolds.

[4SinAir]

I have a stock rear housing off a xr6turbo with a 38mm tial on it up for sale if you are interested

let me know 0405004921