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porting the stock turbine and manifold


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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.

 

http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/th_manifold3inch.jpg

 

http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/th_2013-04-20162432.jpg

 

http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/th_2013-04-20162451.jpg

 

decking...

 

http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/th_SAM_2867.jpg

 

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.

http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/th_20140627_193821.jpg

 

And matching the manifold to turbine ports with a mirror..

http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/th_20140612_175426.jpg

http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/th_20140627_180205.jpg

http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/th_20140612_173819.jpg

 

And deck the manifold all the way to that fat casting mark on the #2 runner

http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/th_20140627_193714.jpg

 

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.

http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/th_20140627_183846.jpg

 

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.

http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/th_20140609_102233.jpg

 

O.D. AT 37mm

http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/th_20140627_190255.jpg

 

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...

http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/th_20140608_184706.jpg

 

Bit is a little long...

http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/th_20140608_184720.jpg

 

Fix that by breaking off the tip...and finishing port with bits...

http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/th_20140608_192744.jpg

 

Used these bits and a drill and harbor freight die grinder work awesome!

http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/th_20140627_190206.jpg

 

The inverted flare bit worked good for smoothing the wastgate entrance...

http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/th_20140627_183259.jpg

 

Before porting...

http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/th_20140608_191249.jpg

 

After...

http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/th_20140627_183228.jpg

 

Finished by smoothing the contacts with some sandpaper..

http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/th_20140627_184230.jpg

 

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
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img [ http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/20140627_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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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.

 

http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/th_20140627_183259.jpg

 

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...

 

http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/th_20140627_224838.jpg

 

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.

 

http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/th_20140627_224934.jpg

Edited by JohnnyWadd
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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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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.

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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
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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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Excellent write up Johnny Wadd

 

Thanks!

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

 

you mean like this?

 

Before....

http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/th_20140627_183259.jpg

 

After...

http://i1187.photobucket.com/albums/z388/starionkiller/12a%20ported%20tourbo/th_20140704_142000.jpg

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