240hoke Posted March 3, 2006 Share Posted March 3, 2006 Hey Guys, There has been lots of talk going around about external wastegates, welding to the factory cast manifold etc etc. I just finished the process of switching over to a TiAL 38mm external gate. I thought I would share what I did. I am running a t3/t04b turbo with a 60-1 compressor wheel, and a stg5 .82 a.r exhaust side. Part used for external gate install: (1) TiAL 38mm wastegate (2) TiAL 38mm w/g flanges (1) Internal w/g block off plate (ATP turbo) (1) Schedule 40 90deg. Pipe from McMaster-Carr (1) 1.5" aluminumized J-bend (1) 3" Doughnut (1) 3" section of 3" aluminized tubing (2) O2 bungs (5) feet of silicon hose (1) V-band Clamp You can add the prices up wherever you find them.. my total came to a little over 400 bucks. I did searching and read about hte proper way to weld cast, the right rod, the preheating to 600, and the slow cooling. But i also searched and talked to people that had had good exprience with welding the stock OEM manifold with mild steel rod and no preheating. I did just that and we will see how long it lasts. I chose to stick the gate under the turbo so i could get a short pipe right off the maifold in the optimum spot, and it also tucks up nice and compact.. Pictures: All laid out: I cut the hole out with a 2" hole saw, worked great, whent marking the hole i put some grease around the pipe and help it where i wanted, leaving a ring to use as a reference. This is the flange from ATP turbo it was 28 bucks. Bolt holes are VERY close to hole, and the pattern wasnt exactly right, I had to drill out the holes one size to fit over the studs. Overall though nice for the price. Doughnut used for DP bends, I had this left over from another project.. Perfect madrel 3" bend, much higher quality then typical dynomax bends from JEG's, which I have had bad exprience with especially the tight radius ones! Mocked up! View from the bottom of the bottom of the car.. mocked up and ready for welding... Welded w/g pipe. Turned the mig up for good penetration throughthe thick metals.. hope it doesnt crack... Heat wrapped and ready to go... My first DP, I welded the 02 bungs too close to the turbo outlet. Ill be tuning with wideband so the sensor needs to be placed about 10" away (around 900 degrees). So ill be redoing... but you get the idea. All bolted up! Im gonna wrap the pipe up too but didnt have the material at the time. Almost back together! This weekend I will be redoing the downpipe, and testing it all out. Also will be getting first impressions on the Competition Clutch Stage 4 6 puck... will give a little write up about it.... Anyway, lemme know what yall think! Quote Link to comment Share on other sites More sharing options...
Guest ON3GO Posted March 3, 2006 Share Posted March 3, 2006 looks great dude.. mike Quote Link to comment Share on other sites More sharing options...
Administrators BRAAP Posted March 3, 2006 Administrators Share Posted March 3, 2006 WOW!!! I absolutely love the visual affect your intake and exhaust system leaves. We always see the polished and chrome parts from everyone else. You know, the “been done before”, syndrome. I personally prefer the more “industrial purposeful racers” look approach to power plant aesthetics, and I truly feel that you hit that mark. From a visual stand point, the wrinkle/satin black, satin aluminum, and gray exhaust wrap combination you have going on is in just the right balance. Gorgeous. Quote Link to comment Share on other sites More sharing options...
nienberg.11 Posted March 3, 2006 Share Posted March 3, 2006 Very nicely done. I'm running the same external gate setup, but it doesn't look that nice at all. You've got the best looking l28 engine bay on here imo. Quote Link to comment Share on other sites More sharing options...
olie05 Posted March 3, 2006 Share Posted March 3, 2006 nice! That waste gate opening up will sound amazing. don't forget to put a heat shield for your brake MC! Quote Link to comment Share on other sites More sharing options...
cygnusx1 Posted March 3, 2006 Share Posted March 3, 2006 Watching the clock waiting for some more hoke vids! Looks awesome. Quote Link to comment Share on other sites More sharing options...
evildky Posted March 3, 2006 Share Posted March 3, 2006 you make me sick, one of these days I'm gonna have to do that Quote Link to comment Share on other sites More sharing options...
DarrellBuddy321 Posted March 3, 2006 Share Posted March 3, 2006 holy crap! That is exactly what i need done! I took my manifold to a shop and they said that they didnt want to do exactly what you did!!!!!! I was wondering if you could help me? This is the only part of my build that is holding me back now. Everything is pretty much done as far as my zx to zxt swap goes. I also have the 38mm tial wastegate with a t3/t04e Quote Link to comment Share on other sites More sharing options...
slownrusty Posted March 4, 2006 Share Posted March 4, 2006 Wow...beautiful stuff! Quote Link to comment Share on other sites More sharing options...
Kennysgreen280zt Posted March 4, 2006 Share Posted March 4, 2006 My roomate has a Tail with open dump tube on his SRT-4. Its fun to scare people with the noise. Mine will be running a similar setup, but on the side of an RB. As always 240hoke, your work looks great!! Quote Link to comment Share on other sites More sharing options...
Supra510 Posted March 4, 2006 Share Posted March 4, 2006 Looks great. I used to have a 280zxt motor in my car and I welded a T04 flange and the wastegate flange with a MIG and regular mild steel wire and never had any issues with cracking so you should be safe. Quote Link to comment Share on other sites More sharing options...
Guest 280ZForce Posted March 4, 2006 Share Posted March 4, 2006 your work is lookin great as always...be sure 2 post up those vids as soon as u get them done Quote Link to comment Share on other sites More sharing options...
240hoke Posted March 6, 2006 Author Share Posted March 6, 2006 Thanks for the comments guys, took the car out today. Open wastegate is incredible. Ive never heard one before! Wow it screams! Heres a pic of my new downipe, lengthened the space to the bend off the turbo so access was better to the nuts and moved the o2 sensors down a bit: Quote Link to comment Share on other sites More sharing options...
240Z_Master Posted March 6, 2006 Share Posted March 6, 2006 Thanks for the comments guys' date=' took the car out today. Open wastegate is incredible. Ive never heard one before! Wow it screams! Heres a pic of my new downipe, lengthen the space ot the bend off the turbo so acess was bettre to the bolts and moved the o2 sensors down a bit: [img']http://gallery.voodoo-people.com/albums/album653/3_inch_downpipe_008_Medium.sized.jpg[/img] Sweet mother of god Austin! Quote Link to comment Share on other sites More sharing options...
oinojo Posted March 6, 2006 Share Posted March 6, 2006 VIDEOS VIDEOS VIDEOS!!!!! PLEASE!!!! Quote Link to comment Share on other sites More sharing options...
240hoke Posted March 6, 2006 Author Share Posted March 6, 2006 Will have more vids by the end of the week Quote Link to comment Share on other sites More sharing options...
b__sosick Posted March 6, 2006 Share Posted March 6, 2006 Austin! That looks great man nice work! Did you get my money order yet? Don't mean to bother, was just wondering. And I must agree. THIS THREAD IS USELESS WITHOUT VIDEO!! Quote Link to comment Share on other sites More sharing options...
turbo_fb Posted March 6, 2006 Share Posted March 6, 2006 VIDEOS VIDEOS VIDEOS!!!!! PLEASE!!!! WTB Videos/soundtrack of that wastegate sound Quote Link to comment Share on other sites More sharing options...
oinojo Posted March 6, 2006 Share Posted March 6, 2006 WTB Videos/soundtrack of that wastegate sound no need i have that same sound of flying bees on my honda:mrgreen: Quote Link to comment Share on other sites More sharing options...
DarrellBuddy321 Posted March 11, 2006 Share Posted March 11, 2006 i noticed you use a header wrap. Is 'there any downside to using it on the oem manifold? Is it more prone to cracking? I want to use a header wrap to help contain the underhood temps but i jsut wanted to have your opinion Quote Link to comment Share on other sites More sharing options...
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