weld an external wastegate to a standard cast manifold? Success!

[shinny]

You're missing a bit!

You should have a metal ring than fits against the piston and seals it.

[C35Rob]

as shinny suggested, you're missing the valve seat.. where did you get the wastegate from? are you sure it's a genuine Tial?

[Martin F]

You're missing a bit!

You should have a metal ring than fits against the piston and seals it.

Image Replaced With URL For Quote http://3.bp.blogspot.com/_8T0m6w7_pvY/T ... om+USA.jpg

I am missing that on my tial wastegate as well then, when welding on the screamer pipe I had exactly the same gap

[dylan5084]

As soon as I got the email I clicked! Have just fitted the ring and it's back to nice hks superdragger noise! What a mug!

Kinda wondered why there was a spare ring....

Cheers lads!
Can go to lanzarotte tomorrow now and not be wondering what I done wrong lol.

[dylan5084]

Will get a road test when I'm back and have put everything else all back together, and get it MOT'd should make some evil noise!

[Martin F]

As soon as I got the email I clicked! Have just fitted the ring and it's back to nice hks superdragger noise! What a mug!

Kinda wondered why there was a spare ring....

Cheers lads!
Can go to lanzarotte tomorrow now and not be wondering what I done wrong lol.

That's good news, it would have been nipping your brain throughout the holiday, Have a good one

[dylan5084]

Job done MOT booked for tomorrow and all built up today and serviced!

[C35Rob]

have you thought about putting some heat shielding around the hot pipe where the wastegate sits just below it?

something like this

http://www.demon-tweeks.co.uk/motorspor ... d-material

it may be worth looking into cutting that sharp bend out on the dump pipe and replacing it with a proper mandrel bend, it won't be good for flow forcing the exhaust gas to turn a sharp corner like that

[dylan5084]

have you thought about putting some heat shielding around the hot pipe where the wastegate sits just below it?

something like this

http://www.demon-tweeks.co.uk/motorspor ... d-material

Looks good, was going to modify an original heat shield aswell.

[/quote]
it may be worth looking into cutting that sharp bend out on the dump pipe and replacing it with a proper mandrel bend, it won't be good for flow forcing the exhaust gas to turn a sharp corner like that [/quote]

It bypasses the turbo fine when I forgot to put in the ring that seals the EWG off, will see how it goes in service had one blast today seemed sluggish but I need to reset my boost controller as well.

[Milo_101]

In my humble opinion, an adapter would make much more of a clean install and offer the same advantages, maybe except for cost.
something like this:



A few more images:
http://s110.photobucket.com/user/023413 ... R.jpg.html
http://s110.photobucket.com/user/023413 ... 6.jpg.html

Just some food for thought.

[dylan5084]

then you need to drop the turbo 2 inches thus the downpipe, which would hit speedbumps more than it does already, youd need oil and water lines made up because it would be out of place too.

[Ryan S]

It would also catch on your slave cylinder. You'd need either a GT4 one or modify the stock cylinder pipes.

[shinny]

In my humble opinion, an adapter would make much more of a clean install and offer the same advantages, maybe except for cost.
something like this.

But a CT to CT external wastegate adaptor like that makes no sense as a product as the market is miniscule... and even if you could buy one, then none of the downpipe, induction, intercooler pipework, oil feed and water lines would line up.

Given his available skills, I think Dylan has absolutely taken the right direct for externally gating a CT series turbo.

[dylan5084]

In my humble opinion, an adapter would make much more of a clean install and offer the same advantages, maybe except for cost.
something like this.

But a CT to CT external wastegate adaptor like that makes no sense as a product as the market is miniscule... and even if you could buy one, then none of the downpipe, induction, intercooler pipework, oil feed and water lines would line up.

Given his available skills, I think Dylan has absolutely taken the right direct for externally gating a CT series turbo.

Cheers shinny building boost really slow now though, 5k rpm for full boost, it used to be 2600-3k for 1 bar. It's holding boost at 1 bar now which is great. I don't know if the internal gate is cracking or not is there any other way to stop it, maybe putting a spot weld on the actuator rod?

[C35Rob]

Do you have access to a mityvac tester? You really need to find out which waste gate is either opening or leaking before doing anything else

[shinny]

Cheers shinny building boost really slow now though, 5k rpm for full boost, it used to be 2600-3k for 1 bar. It's holding boost at 1 bar now which is great. I don't know if the internal gate is cracking or not is there any other way to stop it, maybe putting a spot weld on the actuator rod?

If the internal wastegate was bleeding boost away then you would have already had the slow boost issues using it alone. Sounds like the external gate isn't quite doing the right thing.

[dylan5084]

I've got the boost controller piped to the EWG the way that it's says in their manual.... When I increase gain on the blitz dsbc it doesn't seem to do anything now... It definitely did with the actuator before changing I had it on gain 5 set 25, now I have it at gain 50 and set 70,I've tried setting it in increments of 10, the set changes the final boost up n down, the gain is supposed to be how fast it comes in. It seems to do very little if anything...

[dylan5084]

Do you have access to a mityvac tester? You really need to find out which waste gate is either opening or leaking before doing anything else

I don't have access to one

[2mad]

Very interesting mate ...

[C35Rob]

I may be wrong..

but looking closely at your pics, I'm pretty sure your wastegate is a fake. genuine Tial's use allen head botls for the clamps and yours has got mad long hex heads, also the little link/pivot piece on the clamps is thick and flat on geniune tials, yours look to be thin and beveled as you can see in this pic



they also use aluminium crush washers for the banjo bolts on the ports, yours are copper. also the
banjo bolts look like this -



nice stainless flange bolts and the barb fittings are nice and smooth all round, yours has a weird flat spot directly opposite the barb on the back side.

so yeah... pretty sure you've been sold a fake.

if the car was building boost before you modified it, and it doesn't now, and the only thing you've done to the original toyota wastegate is disable it by pulling the hoses off it then it has to be the "tial" wastegate that is at fault