Garrett GT20 Project

[306Puggy]

That looks considerably better. See how you can now clearly see the circumference of the holes, so you have a better chance of drilling them in the right places?
Crack on with that, it looks to be a good template.

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Havn't been asked to go on strike lately have you by any chance?

Thanks for the input. Yeah, I can definitely see how this will allow me to outline the holes more accurately.

Not sure what you mean regarding going on strike? As in, banned from the forum? Or are you making a joke about my project that I don't get? Sorry but it has fallen flat if so

But yeah, thanks for suggesting to use something sharp to cut the holes out I don't think of these obvious things most of the time!

Looking good, for that sort of stuff, you can always make your holes slightly bigger so you have abit of tolerance incase your hole spacing isn't entirely accurate (which it wont be if your using from cardboard templates). I might have missed this in the thread previously, but what are you going to do about the actutor and clocking the compressor?, 'cos this is gonna be a major issue even for someone with a welder, a bracket will need to be made, and fitted so it doesnt foul, and where your actuator will then sit, is exactly where your turbo outlet for your intercooler is. You could possibly bend the actuator rod and have it behind the compressor which would work, and then get someone to just simply tack it in place on something steel, this would be the option I would go for.

You mention that cardboard templates aren't that accurate, what other methods are there? That someone with limited tools/budget can do ofcourse. And regarding making the holes bigger, I am glad you said that because I was wondering if that would cause a problem if they were slightly bigger but I guess not since you have said it's okay

Was clocking the compressor part of the problem you are mentioning? I found a clocking video on Youtube, the guy said it is a really easy part of the setup. I could take the actuator off and clock the compressor housing with the actuator out of the way, if the actuator's position causes an issue.

I have no idea what to do about the actuator's location I just realised today actually that it is on the front of this unit and the 306 standard turbos have them on the bottom. If you say a given method is the best then that is what I will do, hopefully once I get this together I can then sort the actuator. Luckily I found somewhere a couple years ago that will actually weld (seems to be rare at garages these days).

Right, the next step is going to be to start drilling holes. I have read several methods and I'm not sure which one to use:

method 1: Use a punch to mark the centre of the hole by eye and then use the drill bit that you want for the size of the hole straight off.

method 2: Use a small drill bit to start with and then work up through sizes without using a punch to mark the center of the hole.

method 3: Use a tap to mark the centre of the hole, drill a pilot hole with a small drill but then use the full sized drill bit you want to for the hole.

Method 1 seems to make the most sense to me, I can't see why I would need to do the other bits for this sort of thing. But feel free to correct me.

Also I am going to have to get the adapter plate cut slightly at the top because the turbo actuator arm coupling catches on it which means I can't lay the turbo flat on the plate at the moment. Will a hack saw cut mild steel? Or is that a dumb question?