A couple of things!

TiddlesRX7 · March 05, 2010, 08:44:25 PM

So thanks to Mitch I now have a second hand turbo to replace the one that is on my car. So today I set about porting the wastegate on it to try and eliminate any boost creep like I have been getting. Here are a few pics so you can see the enlarged ports.

Stock ports.

Ported............. ports!

Side view so you can see the back of the port cut away.

So now all that is left to do is install the turbo and give it a whirl! I\'ll keep you posted.

Thanks again to Mitch.:cheers

Prof · March 05, 2010, 08:59:05 PM

Nice bit of porting work there

TiddlesRX7 · March 13, 2010, 09:22:03 PM

Well taday me and a mate set about swapping the turbo out for my replacement one. Big thanks to Ash for helping couldn\'t have done it without him. 5 hours it took us, which I don\'t think is bad considering we did it on the side of the road! Was a really fiddley job to do but we managed with only one real issue. A damaged gasket on the water feed pipe. So after scraping it off with a stanley knife blade and making a new gasket it was replaced and it seems ok.
So after taking it for a 15 mile or so drive all seems well. No leaks i\'ve noticed yet (fingers crossed). The boost is still quite high, around 12psi at its worst/highest but it soon settles down and it isn\'t causing the car to hesitate or missfire. So it seems like its solved my problems. It also seems smoother to drive somehow (maybe just in my head!) like its just dealing with the gasses better. Wahoo for porting!
So the next question is how come my boost controller doesn\'t seem to be able to turn the boost down?

Oh big thanks to M1tch for sorting me out with the turbo and thanks to Prof for letting him clean it up when he was supposed to be helping you out!

Prof · March 13, 2010, 10:48:19 PM

The boost controller willl allow you to control how quickly the boost builds, and should allow you to make higher than spring boost, but you can\'t turn down the boost with it.

The lowest boost the car will make is determined by the wastegate spring / porting / and how easy gas flows in the compressor / turbine.

Putting a restriction in the exhaust reduces max boost, likewise restrictive intake will do the same. If you take the stock engine, modify the air induction and sling a big old zorst on it you will make a lot more boost than the stock 5-6 psi the wastegate spring would normally do.

TiddlesRX7 · March 13, 2010, 11:26:16 PM

Ok I see. Just I don\'t really notice any differance when I alter the settings on my controller. Its an old school one that you tweak a screw in the back of to set low or high and then select on the front of the unit which you want to use. It also has a manual setting knob on the front for quick alterations. I have more of a mess with it and see if I notice anything. Car certainly does feel differant in a good way. Roll on Rotorstock!

m1tch · March 14, 2010, 09:24:32 AM

Did you check the clearance of the flapper on the exhaust flange? Prof has got his spaced out using a cut down spacer and I have a custom bell mouthed downpipe to allow the flapper to open fully, might be worth you taking the downpipe off as well as that plate on the back of the turbo, then grind it down a bit. The plate at the back only allows the wastegate flapper to open a tiny amount, it then gets jammed on the plate meaning it can\'t open more.

Im glad the turbo is ok ^_^ its been mitch cleaned, so its worth an extra 20bhp ^_^

TiddlesRX7 · March 14, 2010, 02:04:43 PM

Yeah I noticed the flap doesn\'t open a huge amount as it fouls on the back plate. But I know with water that type of valve lets through something like 90% of its max flow at around 20% open. Its something like that anyway.
I don\'t think I\'ll be taking it off again to modify it. Well not in a hurry anyway unless I have more problems. The porting seems to be doing the trick for now.

m1tch · March 14, 2010, 04:31:17 PM

Quote from: TiddlesRX7;679000Yeah I noticed the flap doesn\'t open a huge amount as it fouls on the back plate. But I know with water that type of valve lets through something like 90% of its max flow at around 20% open. Its something like that anyway.
I don\'t think I\'ll be taking it off again to modify it. Well not in a hurry anyway unless I have more problems. The porting seems to be doing the trick for now.

Good good

well if you do have issues, its just a case of unbolting the downpipe, unbolt the back plate and see where the flapper is hitting the plate - usually scratch marks in the carbon, just grind it out a bit, but it is pretty amazing how it is find on OEM boost and OEM control!

Did you get an uprated actuator in the end?

TiddlesRX7 · March 14, 2010, 07:28:39 PM

No not yet. Thats the next stage of my plan along with the apexi install and map (only been waiting a year now to find funds for that!). Oh and the purchase of an uprated top mount

m1tch · March 14, 2010, 07:46:46 PM

Quote from: TiddlesRX7;679076No not yet. Thats the next stage of my plan along with the apexi install and map (only been waiting a year now to find funds for that!). Oh and the purchase of an uprated top mount

Yes yes ok ok, I will get about changing my intercooler setup :rollin