Overported my wastegate hole. What now?

[SS_Sean]

Since I sent my 6262 back to PTE to be rebuilt, and got it back, I decided to double-check my wastegate hole port job. I put the turbo in the vice (with plenty of padding) and then bolted the downpipe to the turbo with some prussian blue on the puck. I checked it three times and it is clear the hole is slightly larger than the puck. The GBP 3.5" downpipe has a 1 3/8" puck on it. It's close, but doesn't quite cover the hole in one spot that is about 1/8" long along the edge of the hole. Apparently when I was porting with the turbo on the car the porting job was tilted to one side because of the angle I was at with the turbo on the car. Optical illusion...

I never saw any boost creap, or strange spiking when driving the car. I didn't see any kind of adverse problems. What should I look for? I assumed I'd see erratic boost. I don't know.

If I need to, I could probably get a larger puck, something like a 1 7/16 would barely cover the hole, or 1 1/2" would cover the hole for sure.

What do yall think?

 

[TURBOPOWERED68]

I don't remember the vender but I have seen a plate to fix this problem.
The plate would sit in between the exhaust housing and the DP or Elbow which ever one you have.
Good luck Dude.

 

[Otto J]

You can get a plate that goes between from RJC,IT will have a small hole and you can open it up,it will be easier to gauge also while working on it.
All it will do is slow spoolup from the internal leak,if its only a tiny bit,you may not notice any ill effect

 

[SGRIM]

If possible I would find a larger puck...

If it held solid boost before you should be fine though... I would have to think there would be some negative effect though, however small...

 

[jasjamz]

http://www.turbobuick.com/forums/how-tos/277714-fix-overly-ported-wastegate-hole.html

 

[TurboBob]

if anything it will slow the spoolup down a little.

If spoolup is acceptable, you can leave it in my opinion.

Bob

 

[SS_Sean]

Anyone know where to get a 1 7/16 or 1 1/2" puck?

 

[yullose]

Anyone know where to get a 1 7/16 or 1 1/2" puck?

Last time I bought one it was really expensive... and included the downpipe.

 

[SS_Sean]

Talked with my buddy who is a welder/fabricator, and he's saying we can braze the places that I got a little aggressive with the die grinder. Sounds like this will solve the problem. Thank you for the responses!

 

[yullose]

Good luck with that...

I think you will either:

A) crack the exhaust housing

B) lose the weld due to extreme heat


If it were me, I'd just use one of those plates mentioned above to cover the hole...

I remember seeing oversized WG pucks awhile back, but don't remember where I saw them...

The last thing I would do is weld on it.

 

[Quick6'n'-K.C.]

i second getting the rjc plate, at least it will be fixed permenantly.
If the welds to break when your running 1700°, at least they will stick in the muffler.

BW :smile:

 

[TR Custom Parts]

Are you sure the downpipe is in the exact same position it would be if mounted in the car? Just wondering if the downpipe can be moved a bit. The bolt HOLES are drilled out bigger than the bolts that go into them. If you can rotate it a bit it might be OK???? Could always go to an external wastegate too! Don't know if I would be welding on a $1400 turbo.

 

[turbo nasty]

RJC Racing plate fix my port mess up

 

[SS_Sean]

I'm a little confused here, gentlemen. If brazing holds up to temps of 2500* to melt the brass, then why wouldn't it handle 1400-1600*? The worst that could happen is it breaks off anyway, and goes out the exhaust. I'm thinking I'm going to try it and see if it will work out.

 

[Quick6'n'-K.C.]

Brass (85 Cu 15 Zn) 900-940C 1652-1724F

 

[street6]

if you can't find a vendor who sells a larger puck you could always cut/grind off you original puck and just weld a larger round piece of metal (puck) onto the swing arm.

 

[JRGN]

Sean, There is a rod that you could used to weld the extra space up on the exhaust housing, had my friend who is a certified welder do a friends, he used a nirod and tig it then remilled out the hole. HTH Jr.

 

[streetknight]

Not to rip the thread, but what is the best way to port the waste gate hole? I am experiencing boost creep and a nasty spike.

 

[Quick6'n'-K.C.]

Not to rip the thread, but what is the best way to port the waste gate hole? I am experiencing boost creep and a nasty spike.

Pull the downpipe off and port out enough where the puck will still seal.

You will see a black carbon ring from the exhaust on the turbo, dont over port it or you will be in the same situation as ss_sean

I just use metal carbide bits on a die grinder, i put towels down over the engine compartment so the metal filings dont get on the car.

You can grind it while sucking it up with a shop vac so there is less mess inside the exhaust.
I used supermagnets to collect the excess metal and it seemed to work really well.
BW

 

[Quick6'n'-K.C.]

Not to rip the thread, but what is the best way to port the waste gate hole? I am experiencing boost creep and a nasty spike.

If you have a nasty spike, loosen up the wastegate rod.

What kind of boost bleeder are you running?

The rjc ball and spring style almost eliminates creep on my daily driver.

BW