Radiusing these edges will double the flow. Well known fluid
dynamic fact.

Also drilling them out just a little will increase
the area a lot.

Paul Lamar

Here is what I have in mind. Making a new back cover and moving the
3 inch exhaust pipe over to the waste gate side should allow the waste
gate to open to 90 degrees. This is simple to make.

Paul Lamar

Should work pretty well, Paul.  If you are going to use the stock waste gate
controller it won't be as helpful.  The stock controller has very limited
travel.

Dave Leonard

You are very right. The stock waste gate controller does not have enough travel.
It will have to be manual operated. Unless of course we can come up with another
simple controller. The stock waste gate controller functions on
the difference in atmospheric and manifold pressure and not absolute manifold pressure.
This is not good at altitude where it might open prematurely. There is a spring in
it but a major factor is the pressure or lack of it on the back side of the diaphragm.
Not really designed for altitudes over 8000 feet.

Ideally you would have a $1 microcomputer chip in there taking knock
data, absolute manifold pressure data and manifold temp (perhaps among other
parameters) and controlling the waste gate with a stepper motor.

There I go again... talking with my electronics engineer hat on :)

Paul Lamar
 
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