James Z31 Engine Blueprinting

[85_Z31]

right

I have a 40mm HKS knock off wastegate sitting on my desk.

But first you all say something like " no don't get a cheap one it will fail blah blah blah"

and you are all absolutly correct unless you pull it all apart and rebuild it properly.

Step one is to have a thicker mounting flange made up of 12mm rather than the pissy little 6mm one

Step two is to have a separate stainless valve seat pressed into the new flange so that the valve seat is replaceable like on "real" wastegates

Step three is to have the valve lapped in to the new seat so it actually seals properly

Step four is to take the valve itself and have it clearanced and polished & then coated in nickel never seize before re isntallation

Step Five is to purchase a tial/HKS/turbosmart diaphram( there all the same)

because i have a mate who can do all the machine work for me this will all work out cheap ( box of beers )

and that only really leaves me with the diaphragm.

I got the wastegate for $50 brand new never used so with the custom rebuild it will be as reliable as anything

Pics are still to come of the rebuild

[DylPhil7]

Your a smart fucker James

[85_Z31]

Your a smart fucker James

Nah I'm not but the qualified Masters engineer / Diesel Mechanic / precision fabricator is definitly a smart fucker


I also fully rebuilt a turbo but there are plenty of DIY how to guides online so you don't really need to see all that

Here are some pictures of today's progress, you can see where the casting was really gross and I ported out the flange and merged it nicely. the outlet flange is exactly 35mm in diameter, i can go out to 36mm if i need to but i would prefer to leave some surface area there for the gasket to seat and seal against.



as mentioned earlier the flanges it came with were sub standard so 10mm was employed in place of the 6mm





these are the two fittings drilled into the turbo exhaust housing for EGT and Exhaust Pressure

[85_Z31]

Oh Man

This little fucker 2 bolt flange took me fucking ages but its done now...... Hacksaw was blunt as and I had no cut off grinding discs

oh well its done now.



All ready for some welding !!!!! yus going to have car ready for Akaroa .... I can taste it .... (oh wait maybe that's cutting compound and steel shavings)

[85_Z31]

So the guts of it are as follows

Step one was to have a hole bored directly down onto the manifold at 90 deg to the flange that bolts to the cylinder head

Step two was to have a divider plate welded to halfway up the tube so that everything merged together smoothly

Step Three was to have it all Tig welded in pace , the top of the flange is 60mm vertical distance above the mounting boss for the heat shield on the t3 flange

Step four was having the 6mm flange the WG came with welded to a 10mm flange to provide a solid 16mm of beefyness and then welded to the pipe

the pipe is 3.5mm wall and machined to be a perfect fit to the ID of the hole in the flange

The waste gate was positioned to give ample clearance to surrounding stuff like the body & valve cover.

This was done by a pro welder who has been welding cast iron for 20 years and cost me $160


I feel like i have come up with a really tidy and professional installation I hope you guys like it

[Bartman]

Nice!

[gingofthesouth]

Looking good bro. You will be enjoying the fruits of your labour shortly!

[dirtyleppa]

nice work. ready for akaroa? hope so

[85_Z31]

I hope so,

I'm yet to go for a drive without something bad happening. This will definitely solve any over boost problems.

[dirtyleppa]

best get it done well before then will be stink for it not to be there. so many people are amping to see it