Barry Gardner wrote:

Paul,

I have my turbo off my car (that's like your's in the picture you
put on the net) and I'm going to port the wastegate. I'm thinking
of replacing that smaller wastegate with a larger disk so that I
can port it out more. Do you think that's viable?

I do agree the disk needs to be larger.
I will have to take a closer look at the way that disk is captured 
by the lever. That is the trick. I don't think it is welded on.
I think it was made in one piece and then it was forged some
how. Probably by heating the end of the pin and applying tons 
of pressure to form the a loose rivet head. See the picture below. 
You might have to make a couple of prototypes and test them 
to see if you can make a workable device.

Even if you port the existing hole to nearly the same size as the
wastegate, these turbos are prone to overboosting due to
inadequate wastegate size. Guys will open up the intake and get
rid of the catalytic converter, only to find the boost goes from
5.5 psi stock to 12 psi or more. Blown engine apex seals can
occur because the mixture is not rich enough to cope with that
much boost.

I was thinking all I'd need would be a disk of stainless steel
about the size of a half-dollar, maybe 3/16" thick. I could
enlarge the wastegate to encompass most of that shoulder area in
the picture to the left of the wastegate in your picture. Are
there any list members who have a dinky piece of stainless in
their scrap pile they'd be willing to donate to my project?

What do you think about the idea of replacing the wastegate
flapper with a bigger size?

Barry Gardner
Wheaton, IL

 
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