Porting the wastegate

[paulwatkins]

What exactly does it mean when you say "porting the wastegate"?

What is involved?
Is it something that is done to the turbo?
How much does it cost? How long does it take?
Who does it? Is it something I can do myself? Or are there companies that can do it? Anyone in the Bristol area you can recommend?

I've got the peco exhaust to fit at some time, and while the components are disassembled is it worth getting it done now? Or is it something I can do again in the future (if I get turbo creep) by just taking the turbo off (It should be easier next time!)

Cheers guys,
Paul

[Enright]

Paul,

It involves removing the pre-cat from the side of the turbo, and simply boring out the wastegate hole by about 4mm, using a commonly available drill attachment from B&Q.
This then (safely) removes the restriction of airflow through the wastegate, allowing it to keep up with the main flow of air through the turbo. Under normal circumstances with standard equipment it's not an issue. But a 2 1/4" exhaust allows up to 26% more volume through it than a standard 2" system.
The free-flowing exhaust and a K&N drop-in replacement filter let the engine breathe so much better that it takes it above the flow capacity of the wastegate hole.

Cost to you: just about £20 - if that - for the set of grinding stones.
Time for you: about an hour, you lucky bugger (for anyone else it's days or even weeks of fighting to gain access to it)!
Who does it/should you?: Do it! In your situation it's a no-brainer.
Meaning: you already have the turbo off, and it's well within your capabilities.

Follow the write-up that I did in the Stiffy thread from here onwards.

It was written in a very similar vein to your engine project thread. i.e. from the POV of a complete novice attempting an unfamiliar job for the first time and having to ask about unexpected problems/issues along the way.
Hope it helps.

[GeoffSmith]

I there is ever a possibility of you going for a larger exhaust then DO IT NOW! It shouldn't affect things too much with a standard exhaust so you're better off doing it now when all the bolts are undone.

The wastegate is the turbo bypass valve and it passes exhaust gases away from the turbo to limit the boost. If you change the original (restrictive) exhaust then there is less resistance, so more pressure across the turbo primary and more boost; the wastegate has to open wider to limit the boost to a set level and there comes a time when it is wide open and the boost runs away with itself (boost creep). Opening the wastegate port out wider (e.g. with a small abrasive wheel) allows the wategate to pass more gas and allows it to keep the turbo in check. Do a search on porting - Neil did a good write up somewhere. It shouldn't take too long or cost too much.

Geoff

[Enright]

Ha! Revenge!

[GeoffSmith]

FLPT

[paulwatkins]

Thanks for the info guys.

Thats a great write-up Neil.....think i'll be popping down to B&Q this weekend and then "porting my wastegate"!!!

I'll post pics on how I get on with it.

Cheers, Paul

[paulwatkins]

Sorry guys a 'novice' question if I may?

What sort of speed to I need to run the drill at with the grinding stone attached?

Thanks, Paul

[Enright]

Erm, can't remember. I just spun it up pretty fast and leaned on it for about half an hour! Took quite a bit of effort too.

Maybe there's an ideal speed - it could be printed on the packet. Speaking of which I'll snap a pic of the set so you know which ones to look out for.

Novice question from me too: does anyone know what "FLPT" means?
I'm completely baffled!

[paulwatkins]

Novice question from me too: does anyone know what "FLPT" means?
I'm completely baffled!

Here's Timmo's list from a previous thread:

AFAIC = As Far As I'm Concerned
AFAIK = As Far As I Know
BFD = Big F*cking Deal
BFN = Bye For Now
BFO = Blinding Flash of the Obvious
BO = Brain Overload
BOHICA = Bend Over Here It Comes Again
BOKYAG = Bend Over and Kiss Your Ar*e Goodbye
BRB = Be Right Back
BTSOOM = Beats The Sh*t Out Of Me
BTW = By The Way
CU = See You
CUL8R = See You Later
CYA = Cover Your Ar*e
DITYID = Did I Tell You I'm Distressed
EFLA = Extended Four Letter Acronym!
FAQ = Frequently Asked Question
FC = Fingers Crossed
FCFS = First Come First Served
FEAR = F*ck Everything And Run
FIIOH = F*ck It I'm Outta Here
FOAD = F*ck Off And Die
FUBAR = F*cked-Up Beyond All Recognition
FUCT = Failed Under Continuous Testing
FWIW = For What It's Worth
FYI = For Your Information
GMTA = Great Minds Think Alike
GTRM = Going To Read Mail
HSIK = How Should I Know
HTH = Happy To Help
HTH = Hope This Helps
IAE = In Any Event
IANAI = I Am Not An Idiot
IBK = Idiot Behind Keyboard
IIRC = If I Recall Correctly
ILF = I'll Look Forward
IMCO = In My Considered Opinion
IMHO = In My Humble Opinion
IMNSHO = In My Not So Humble Opinion
IMO = In My Opinion
INAL = I'm Not A Lawyer
IOW = In Other Words
IRC = Internet Relay Chat
IRL = In Real Life
IYKWIM = If You Know What I mean
JFYI = Just For Your Information
J/K = Just Kidding
L8R = Later
LMAO = Laughing My Ar*e Off
LMKOAP = Let Me Know Of Any Problems
LOL = Laugh Out Loud
LOEL = Laugh Out Extremely Loud
MMP = More Money Please
ML = Mailing List
NBD = No Big Deal
NFW = No F*cking Way
NIFOC = Nude In Front Of Computer
NIFOK = Naked In Front of the Keyboard
NOYB = None Of Your Business
NRN = No Reply Necessary
OIC = Oh I See
OOH = Out Of Hand
OOTB = Out Of The Box
OTL = Out To Lunch
OTOH = On The Other Hand
PITA = Pain In The Ar*e
PMFJI = Pardon Me For Jumping In
PMJI = Pardon My Jumping In
POV = Point Of View
PTB = Powers That Be
ROFL = Rolling On Floor Laughing
ROTF = Rolling On The Floor
ROTFL = Rolling On the Floor Laughing
ROTFL = Rolling On the Floor Pissing Myself Laughing
ROTFLMAO = Rolling On The Floor Laughing My Ar*e Off
ROTFLOL = Rolled on the Floor Laughing Out Loud
RSN = Real Soon Now
RTFM = Read The F*cking Manual
RTM = Read The Manual
SEP = Someone Else's Problem
SGI = She'd Get it
SITD = Still In The Dark
SLAP = Sounds Like A Plan
SNAFU = Situation Normal All F*cked-Up
SOL = Smiling Out Loud
TANJ = There Ain't No Justice
TANSTAAFL = There Ain't No Such Thing As A Free Lunch
TBH = To Be Honest
TIA = Thanks In Advance
TIC = Tongue In Cheek
TLA = Three-Letter Acronyms
TLTBT = Too Ludicrous To Be True
TPTB = The Powers That Be
TTFN = Ta Ta For Now
TTYL = Talk To You Later
VPL = Visible Pantie Line
WGFF = Who Gives A Flying F*ck
WIC = Where I'm Concerned
WIMP = Washed-up Information Media Phobe
WOA = Work Of Art
WOB = Waste Of Bandwidth
WRT = With Respect To
WTF = What The F*ck
WTFIGO = What The F*ck Is Going On?
WTH = What The Hell
WYSIWYG = What You See Is What You Get
YAM = Yet Another Meeting
YCHT = You Can Have Them
YMMV = Your Mileage May Vary
ALDL Assembly Line Diagnostic Link
BOV Blow Off Valve (AKA Dump Valve)
CTS Coolant Temperature Sensor
DI Direct Ignition
ECM Electronic Control Module
EGR Exhaust Gas Recirculation
EGRCS EGR Control Solenoid
ESC Electronic Spark Control
EST Electronic Spark Timing
FR&PR Fuel Rail and Pressure Regulator
HEI High Energy Ignition (N/A Specific)
HVL Hydraulic Valve Lifters
IAC Idle Air Control
IDRM Injector Dropping Resistor Module
N/A Normally Aspirated (AKA A Clemo)
MAP Manifold Air Pressure
MAT Mass Air Temperature
MBC Manual Boost Control
MPFI Multipoint Fuel Injection
PAS Power Assisted Steering
PCV Positive Crankcase Ventilation
PSPS Power Steering Pressure Switch
STCS Secondary Throttles Control Solenoid
TPS Throttle Position Sensor (Switch)
VSS Vehicle Speed Sensor
WS Wastegate Solenoid


Geoff's "FLPT" isn't there! Looks like he's AGAIN!!

[GeoffSmith]

Neil, it's one of Enright's quotes! (FLPT = slow typing)

Firmly back on topic, I always have trouble finding your porting write up and pictures Neil. It would be better to have it in the "upgrades" section (more important upgrade than a heated seat IMHO) or as a seperate sticky thread after Paul has added his tenpeneth and pictures - any chance Mr. V?

Geoff

[dapinky]

It all depends on the grinding stones you get as to the appropriate speed to use!

The 'variety pack' that they nornally sell at the DIY stores will each be made out of a different material (different colours!) for different uses.

It also depents on the material your grinding out.

I don't know if its steel or cast iron (haven't got that far with mine, yet - too many distractions ) so can't advise.

If you use the inappropriate stone/speed it can lead to lots of exciting things happening. These range from lots of dust, to shattered bits of stone whizzing past your ears at great speed!

If its a cast iron part, move slowly with gentle pressure. For steel, you can go faster and press harder. Take it steady, don't let it overheat and remeber to wear goggles!!

[GeoffSmith]

Don't go for the cheapest you can find either. I had one where the shaft was off centre or bent and all it did was shake my teeth out (but luckily they didn't break when they hit the floor and after brushing them off, they slotted back into place)

Dave, it might be worth showing Paul!

[Dico]

By the pack of grinding stones from B+Q as Neil says, iirc ( ) its a pack of four which cost £10.
The cone shaped one is the one to use, perfect size. As neil says, around half an hour including rest time

[dapinky]

Geoff...... now why didn't i think of that!



I've got every faith in Pauls ability to do this one, or i'd have leapt in with the offer.




Paul, that said, if you have any problems, give me a shout

[Enright]

Neil, it's one of Enright's quotes! (FLPT = slow typing)

Firmly back on topic, I always have trouble finding your porting write up and pictures Neil. It would be better to have it in the "upgrades" section (more important upgrade than a heated seat IMHO) or as a seperate sticky thread after Paul has added his tenpeneth and pictures - any chance Mr. V?

Geoff

Hahaha, damn that's a good one!
Don't get me into any more trouble though, I was only quoting Sy.
It's bad enough being a Stupid Boy already!!!

On a slightly more serious note, the problem is Geoff: my porting wastegate job was done in conjunction with test-fitment of a Stiffy, because nobody had ever tried it before on an a/c equipped car.
That's why it was sort of tacked-onto that thread, starting at post number 116 and rambling on (for a good few pages) afterwards.
It seems as though it's now become THE quoted how-to-do-it-example, maybe because nobody else waffled on about it as much as me!!!
And much the same way that Paul's engine rebuild will probably become the quoted guide to help people out with any similar problems.
But it was never supposed to be a project on it's own, more just a solution to a personal problem <insert your own joke/s here>, and helping Stevo with testing out of his upgrade.

Edit: Oh I completely forgot - I took a pic of the grinding stones, with the important one to the right of the packet. They're made by Bosch, and Dico's memory of the price was a lot clearer and closer than mine - bonus eh Paul?!?

[GeoffSmith]

My thinking was that, since the Peco deal, there are enough people getting creep to justify having a seperate, dedicated write up. Maybe Paul and you between you could put something together as a seperate thread which someone might make sticky or into an upgrade write up. Hopefully you'll do this before the weather improves and I get round to porting mine!

BTW, I've posted something on an interesting idea on Seloc: WikiLEC.

Geoff

[paulwatkins]

Thanks for al lthe info guys!
I'll pick up the same Bosch set of stones this weekend and set to it.

I'm sure I can manage this task, I'll just have to dig my hand drill out and get some elbow grease while i'm at B&Q

I'll take plenty of pics as I go so that they can be inserted into a 'how to' guide.

TTFN,
Paul

[GeoffSmith]

I'll take plenty of pics as I go so that they can be inserted into a 'how to' guide.

[Sy V]

...It would be better to have it in the "upgrades" section (more important upgrade than a heated seat IMHO) or as a seperate sticky thread after Paul has added his tenpeneth and pictures - any chance Mr. V?
Geoff

Sounds like a plan to me, but it would be easier if all the text is edited into one block, and sent to me, I'll then nick and add Paul's pictures and send the whole thing to the resident angel for HTMLing.

[lotuska]

I don't know if this is of any help, but it does have some good pictures...

www.aaroncake.net/rx-7/s4wastegate.htm