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porting the stock turbine and manifold

the sequel wastegate porting porting

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#1 JohnnyWadd

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Posted 27 June 2014 - 09:41 PM

Went after my stock turbine housing and manifold again. After getting awesome results by porting the manifold and turbine at work with an air powered grinder, and decking the mating surfaces almost 2mm each at the machine shop I decided to port the wastegate hole and deck the manifold 2 more mm.

Here is my original porting...5k plus miles on this on a 12a and 14b. Not gong on a 14g do5h (so bigger exhaust and intake wheel)
Almost 3 inch...on the manifold and turbine inlet and turbine outlet. Also used larger studs on the manifold to ensure perfect clamping force because al that porting made the gasket area thin.

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decking...

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For my next phase I just did more of the same....

For the manifold  quick resmoothing of the casting marks. Pretty much to the point of it looking like tubing. Eliminates hot spots and stress risers.
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And matching the manifold to turbine ports with a mirror..
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And deck the manifold all the way to that fat casting mark on the #2 runner
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Next  went after the wastegate hole.The flapper is 37mm , so I went with a 1 inch or just under 26 mm porting. I used a step drill to start a nice centered hole and finished with carbide burr bits.

Grind here to allow the flapper arm to be pulled outta the way.
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This lets you tape or otherwise secure the flapper outta harms way. I used a Tim's turbo business card. Seemed fitting since he gave me a line about how the arm has to be cut to port the wastegate. Liar.
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O.D. AT 37mm
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See the 1 inch bit clears the flapper, but grinding the chamber lets it get outta the way a little more. And increase the internal volume of the chamber so it can flow a little more maybe...
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Bit is a little long...
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Fix that by breaking off the tip...and finishing port with bits...
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Used these bits and a drill and harbor freight die grinder work awesome!
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The inverted flare bit worked good for smoothing the wastgate entrance...
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Before porting...
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After...
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Finished by smoothing the contacts with some sandpaper..
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The concept with the original porting and decking and grinding the heck outta the manifold was to allow more flow with all the porting for better high end power and better spool, the decking was to put the turbine wheel closer to the exhaust valve and to decrease the internal volume of the manifold so the engine exhaust could fill it quicker and thereby get the turbo moving quicker. Grinding off all the casting marks and heat shield mounts was to lighten it and reduce thermal mass and hot spots. Also make it look like a header especially when wrapped.

The wastegate porting is to reduce boost spikes and allow a little better boost control. Its "experimental" right now because it can maybe allow exhaust pressure to push the wastegate open now that it has a larger surface. We will see what happens. I don't think I will be pushing it hard enough for that to happen though. Also the pressure on either side of the flapper will not be of such a difference with a 3 inch exhaust and all this porting. Overall I think it will help keep turbo speed consistent much like a fast acting blow off valve.

Edited by JohnnyWadd, 27 June 2014 - 10:33 PM.






#2 Shelby

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Posted 28 June 2014 - 12:16 AM

img [ http://i1187.photobu...627_183259.jpg]


couldn't get the pic to post but if you look at the area aroound the flapper in let
there is a lot of room to remove  metal to create a bell port to the flapper , this
will create a ventura effect and speed up the gas flow thru the  flapper hole  giving a good 40 % flow increase

all your porting will increase spool up  time , porting the flapper port hole is where ALL performance increase  comes from at top end

for got to say  dam good job
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#3 JohnnyWadd

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Posted 28 June 2014 - 12:58 AM

View PostShelby, on 28 June 2014 - 12:16 AM, said:

img [ http://i1187.photobu...627_183259.jpg]


couldn't get the pic to post but if you look at the area aroound the flapper in let
there is a lot of room to remove  metal to create a bell port to the flapper , this
will create a ventura effect and speed up the gas flow thru the  flapper hole  giving a good 40 % flow increase

all your porting will increase spool up  time , porting the flapper port hole is where ALL performance increase  comes from at top end

for got to say  dam good job

Thanks. The picture I think you mean this one.

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And yes I used that inverted flare bit special just to bell mouth that part. Lets you not have to tilt the heck out of the high speed cutter to get it at the right angle.

One other thing to be wary of is the flapper MIGHT hang up. The reason is the hole being so big and the flapper is not perfectly centered you can get this...

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Now with the exhaust gas pushing on the flapper and the fact that the weight of it tends to tilt it downward due to the orientation on the car, I think its a non issue. But just in case I am polishing it at the sharp point and on the flapper to make it too smooth to hang up. Tim's turbo shop said you cannot port the flapper hole because of this reason as well as telling me the arm had to be cut off and rewelded. A few minutes with the dremel and some polishing compound should do the trick.

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Edited by JohnnyWadd, 28 June 2014 - 01:10 AM.


#4 Shelby

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Posted 28 June 2014 - 01:51 AM

my point  was you can go further  with  the bell port then you did.
once you hit the set boost level ALL exh gas has to exit   by way of the waste gate flapper hole

look I-m not trying to rag on your work , it  is great
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#5 randy

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Posted 28 June 2014 - 05:32 AM

Great work man

#6 importwarrior

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Posted 28 June 2014 - 05:48 AM

I vote FAQ

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#7 JohnnyWadd

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Posted 28 June 2014 - 12:45 PM

View PostShelby, on 28 June 2014 - 01:51 AM, said:

my point  was you can go further  with  the bell port then you did.
once you hit the set boost level ALL exh gas has to exit   by way of the waste gate flapper hole

look I-m not trying to rag on your work , it  is great

I know man. I got the point and wasn't insulted. That's where I really let the bit tear into it . Hard to get in there unless I go back In with a bigger bit. I will show you a new picture.

#8 importwarrior

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Posted 28 June 2014 - 01:03 PM

again great work.
my stock manifold and turbine had most of
this done and it made a noticeable difference
in performance.

i also was running a TD06 in it as well.
good spool up all the way to RedLine

Edited by importwarrior, 28 June 2014 - 01:09 PM.

B-71 87 TSI ~ RIP

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#9 Shelby

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Posted 28 June 2014 - 02:22 PM

the size of the turbine wheel will aid in  spooling the turbo but does nothing about removing  exh gas AFTER  set boost is reached , with an internal waste gate it ALL then depends on the flapper port size
and passage shape
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#10 markhansenconquest

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Posted 29 June 2014 - 01:03 AM

good write up....now I know how to do mine...........
thanks ...........

Edited by markhansenconquest, 29 June 2014 - 01:04 AM.


#11 SOTTY

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Posted 29 June 2014 - 11:59 AM

Excellent write up Johnny Wadd
Winning at U.S hot rod and classic car shows with a Mitsubishi since 2009

#12 IntercooledFlatty

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Posted 30 June 2014 - 08:28 AM

;)
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          MOPAR POWERED

#13 JohnnyWadd

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Posted 04 July 2014 - 05:16 PM

View PostSOTTY, on 29 June 2014 - 11:59 AM, said:

Excellent write up Johnny Wadd

Thanks!

View PostShelby, on 28 June 2014 - 01:51 AM, said:

my point  was you can go further  with  the bell port then you did.

you mean like this?

Before....
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After...
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#14 importwarrior

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Posted 25 November 2014 - 05:54 PM


B-71 87 TSI ~ RIP

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