External Wastegate On Rb20 Std Manifold

[Bsa]

hey everyone im wanting to weld my wastegate on the stock manifold. now im wondering what is the best way to do it iv searched google aqnd only got one thing and i dont really want to go that way. http://www.driftworks.com/forum/technical/142373-rb20det-manifold-external-wastegate.html post 9. i sat it on there and its not attractive asking for defect. is there any other way about it?

cheers

Edited November 1, 2011 by Bsa

[zebra]

buy an internally gated turbo?

and its not a defect if its plumbed into the exhaust

[Bsa]

I just bought a external gate turbo and in not happy with the highmount looks better down low I think. The fab part is easy I can to it if it's not a defect I'll just run a pipe and have it a bit out of the way I'm doing it tonight I'll post step by step with photos

[dori34]

mount the gate off the rear housing.

what size gate are you running?

[BOOZTJUNKEY]

Yeah post up pics I'm keen to see how u go cause I have been contemplating this as well ....

What are you gunna make the flange out of ??

Also if h know how to tig u could probably use the tig and do a neat fuze/weave to get the flange on and help with preheating then when it's hot enough hit it with the mig or stick

[Bsa]

ok so job took a hour and turned out well here is how i did it

step 1- drill a hole dead center of the flange i drilled mine at 37mm with a slugger so i could shape the pipe to sit on top should look like this

step 2- now you have your hold get a hammer and something to bash the edge of the cast i used a centre punch it will just crack and leave a nice edge

step 3- clean the cast with a flap disk so you have a nice surface to weld to otherwise life will be hard

step 4- shape your pipe so its a nice fit i got a bit anal about this because i used a tig if you mig it dont matter so much then lightly pre heat so it just off touch hot tack in place

step 5- heat so its hot around 150 to 170 degrees atleast 100mm dia around welded area to be safe heat it slow hot it heats right through then weld four points about 5 mm long to ensure it dont move while fully welding. heat again should be around 190 degrees now time to weld. if using tig do not fuze must use filler rod and it might promote cracking.i used 1.2 mig wire for this so i got a nice pool should look like this

step 6- get the oxy back on there to maintain a even heat the cast will cool faster and crack we dont want this. every 15 mins do this just for less periods of time so it cools even.

step 7- welding on wastegate flange set to desired angle i aimed mine at a 45 degree andgle to make plumbing into exhaust easier no need to heat this

step 8- post heat agian then wrap in a leather blanket or something that will help it cool slow this is the most important step otherwise you wasted your time dont remove untill touch hot

step 8 install on car

and thats it i dont recommend trying this unless you understand heating and cooling of metals as welding cast can be tricky. ensure that all swarf and other bits of shit are removed so no turbine damage. ill be happy to do it for people that are not confident hope this helps people in the future ill be heat wrapping mine. it will be put to the test on friday 17 psi should give it a go.

parts needed-

mig or tig. stick is just to messy and cant be controlled that well

1.2 mild steel wire for tig or .9 ms wire for mig

mag drill is best or get it machine cut

oxy or propane

length of desired pipe i think 40 mm would be max 38 was a perfect fit i used a 45 degree angle

leather blanket or simular kilm would be best

im using a 35mm turbosmart gate and a td06 turbo was a bitch to get in but worth it

any feed back welcom few more ideas and this could be a really good thing

cheers blake

[zebra]

Came out well

[Bsa]

yeah im happy with it tho i made the pipe to long and almost hit the chassi so i cut and shut it with the stick at home turned out good find out how well it controlls the boost soon

Edited November 2, 2011 by Bsa

[Bsa]

Well everything stayed together even with 1.8 bar through it controlled boost perfect total cost including wastegate was 160 150 for turbosmart gate 10 for pipe perfect upgrade for those that like money

[boostn0199]

Great work looks good and most important thing did the job.

[BOOZTJUNKEY]

Hey mate do u think it's possible to get a 44 mm gate setup the same way ?

[Bsa]

Yeah just means you will have to use a die grinder to open up the back to get sufficient flow and be sure to heat well as because you taking out a lot of material it will want to warp the manifold. What's the turbo your running

[BOOZTJUNKEY]

28 76r to start with I got it preety cheap so I wanna see how well it makes the power I want .... If it doesn't cut it I will be using a kando tdo6

[Bsa]

Will you need a wastegate that big it will be a lot of work the 38 mm pipe suited it perfect! I guess you could flare or shrink the pipe to suite the gate. I mean 38 to suite manifold then it opens up to 44 similar to how they flair you exhaust pipe if you know what I mean.

[BOOZTJUNKEY]

Yeah I actually thought that myself just flaring I out because it looks alot easier to do a 38 then a 44 lol I'll have a bit of a play mate I have 3 spare manifolds Here so will probably do both and see which looks like the goods I'll post up some pics an results when done for future reference thanks heaps mate

[Bsa]

Where abouts you from I can give you a hand if needed

[BOOZTJUNKEY]

Hey man I'm at hilcrest.... Where are u ? Be interested to see how u set up your screamer and talk to u bout jez doing a tune for me :-)

[Bsa]

My screemer was just a rash decision I'm plumbing it in today to make things legal I'm on the central coast I'm sure jez you be happy to talk to you about a tune he is very switched on and knows what he is doing. Message me if you need some help with the mod 0449831518

[BOOZTJUNKEY]

No worries Blake I will do :-) thank again

[Bsa]

How did you go mate