16 replies to this topic

[BoostedS70]

so i found this neat guide on this website http://www.aaroncake...s4wastegate.htm , about wastegate porting. im preparing for a 50 trim install and looking at the wastegate hole its patheticly small. so would somthing like this work for opening up the wastegate hole on the 50 trim and welding a bigger flapper on ther. the only thing I see that confusing me is the wastegate flappers seem to be loose and jointed. and if you were to weld it it would no longer be loose or jointed. hope some of you guys with big turbos chime in. thanks

[fischmama]

BoostedS70, on 31 December 2011 - 07:37 AM, said:

so i found this neat guide on this website http://www.aaroncake...s4wastegate.htm , about wastegate porting. im preparing for a 50 trim install and looking at the wastegate hole its patheticly small. so would somthing like this work for opening up the wastegate hole on the 50 trim and welding a bigger flapper on ther. the only thing I see that confusing me is the wastegate flappers seem to be loose and jointed. and if you were to weld it it would no longer be loose or jointed. hope some of you guys with big turbos chime in. thanks

I've increased the size of the wastegate hole, but no modification of the flapper was needed since it was quite a bit larger than the original hole.

[BoostedS70]

how much larger should i make mine its really small i deff dont want any over boosting

[BoostedS70]

what do i do about getting the turbo on the manifold the flanges are completely different. I found this on ebay http://www.ebay.com/...535419956077287 but it looks like the stock volvo flange and i dont understand how this will bolt or even make a difference. also what do i do about the studs in the manifold do i remove and then drill the holes larger.

[URO_S60]

I know you will have to mill the lip off the flange and make it flush (and will have to run a gasket to prevent leaks which was the reason for the lip to be gasketless).

[lookforjoe]

How about pics of what you bought. Since we have no crystal ball, it would help provide suggestions.

[BoostedS70]

i dont know how to post pics but here is the link http://www.godspeedp...ced71v4467ec6u1

i know people are gona rip me for getting a cheap turbo but i have had 2 of these turbos on 2 seperate cars and they are awsome. 30,000+ hard miles on my DSM on a 16g and no issues. it also has 1 year waranty and only cost me 200 so im not gona complain.

[URO_S60]

I ran a godspeed 20g on my DSM at 23psi and beat the piss out of the built engine and tranny held up as well as the turbo, only down fall were the 4 bolt axles, so I won't be ripping on the choice of turbo as I am going down this road once I PCS from Korea to (as of right now) Fort Drum, NY.

Just make sure you get a turbo timer or let the turbo cool down and keep up wioth oil changes and you can't go wrong. Like you said even if you have to do a rebuild on the turbo once a year it still in the long run of things ends up being cheaper than buying a $1k turbo. Just don't sell your turbo you have now incase you need to swap out/back to what you have now.

[lookforjoe]

I dunno. Looks like the same as every other T3 flange. The OBX adaptor should be all you need in that case - if you're not removing the exhaust manifold - otherwise grind/mill the lip off the manifold & it should bolt up. The bolt holes in a T3 flange are slightly larger ID, but that doesn't mean you can't still use the Volvo sized hardware - it'll just have a little 'wiggle' room as you tighten it down.

[fischmama]

^ correct.

One piece of advice... I recommend going out and buying the ATP Ultimate wastegate. The flange thing on these turbos suck, the flapper has no room to open more than a few mm. It was not enough for me to stop it from overboosting.

[B Mac]

Double correct ^

Getting the proper wastegate setup is huge when runnning a turbo and boost control is the only thing between driving and walking home.

Also, the factory volvo hardware is M8x1.25...most turbos and adapter flanges use an M10 thru hole. I tapped the two bottom holes of my manifold for M10x1.75 so that the turbo/gaskets/adapter wouldn't float around in the slack of the bolt holes.

[slithereyes850]

First off, are you running a T04E 50 trim???? If so that flange is a waste, trust me it will not fit behind your engine. the flange raises the turbo to much and gives it an incorrect angle which causes it to hit the firewall. What I simply did was what URO_S60 stated, mill the lip off the factory manifold put a gasket and tighten it down. Hope this helps

[URO_S60]

^ Can you show him a photo or two from when you installed yours and an after shot showing how the fitment is to reassure him (and me. as I will be going with a 50trim later this year) how things "should" fit once everything is done. I know everyone has their own issues with their own cars and there can be some variables but lets see how yours is if you don't mind...?

[fischmama]

slithereyes850, on 04 January 2012 - 02:23 PM, said:

First off, are you running a T04E 50 trim???? If so that flange is a waste, trust me it will not fit behind your engine. the flange raises the turbo to much and gives it an incorrect angle which causes it to hit the firewall. What I simply did was what URO_S60 stated, mill the lip off the factory manifold put a gasket and tighten it down. Hope this helps

No issues here and I know that the 50trim will clear the firewall too. The only place that could be an issue is the trans mount. I had to grid it down a bit to get proper clearance. The flange adapter does not change the angle at all. Its probably less than 5mm thick.

[slithereyes850]

URO_S60, on 04 January 2012 - 02:35 PM, said:

^ Can you show him a photo or two from when you installed yours and an after shot showing how the fitment is to reassure him (and me. as I will be going with a 50trim later this year) how things "should" fit once everything is done. I know everyone has their own issues with their own cars and there can be some variables but lets see how yours is if you don't mind...?

Sure I'm still at work but when I get home ill pull some pictures up for you, and maybe it was because I was trying to use the obx flange which is a lil more than half an inch thick and also yes I had to grind my trans mount as well but since I have a lot more torque in my setup I broke the aluminum mount so I'm now in the process of making my own out of chromolly tubing.

[850wagonT5]

slithereyes850, on 04 January 2012 - 02:23 PM, said:

First off, are you running a T04E 50 trim???? If so that flange is a waste, trust me it will not fit behind your engine. the flange raises the turbo to much and gives it an incorrect angle which causes it to hit the firewall. What I simply did was what URO_S60 stated, mill the lip off the factory manifold put a gasket and tighten it down. Hope this helps

I'm using that exact turbo and that exact flange. It's a tight fit - but it does fit. I had to dent in the heat shield material, as it's thicker than it looks. But I didn't have to dent the firewall.

Also, porting the wastegate flapper hole on that turbo (China/ebay internally gated T3/T04E) is REQUIRED for stable boost levels and to prevent spikes. I first installed it as it came shipped, and had all sorts of boost issue problems. After a couple weeks, I took it off, and hogged out the flapper hole with a carbide bur. Reinstalled, and boost was smooth and stable.

A lot of people misdiagnose this as the actuator.

[B Mac]

My .70a/r compressor housing fit perfectly and is a tight squeeze but doesn't touch anything. Only thing I had to do was make a new rear trans mount.