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Whats the smallest external wastegate I can get away with?

None? Just weld it up. ;)

What are your plans boost wise, and how is the gate mounted. Will it be a screamer? It's all dependant on flow through the gate. I wouldn't go smaller than 40mm personally, preferably 50mm+.

Any chance you could post up a pic of your modifications to get the rb25 manifold onto the rb26 head as I'm currently going threw the same process and after ideas.

Cheers

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