Garrett GT20 Project

[306Puggy]

Right, time for a major update! Decided to get my arse in gear and even though I had been told not to, clean the mating surfaces of the turbo:





They're not totally clean looking but they are nice and smooth. Still not sure of the reason not to do this? As long as you use a fine enough grade of sandpaper (>400) then I can't see how it could cause problems. Surely the carbon will just build up a natural seal if there are any leaks, on the exhaust side at least.

Next job on the list was to remove all the exhaust studs from the turbine exhaust housing:



This proved to be easier said than done. Using heat, candle wax and leverage I got two of the three out. The third one was a right bitch to do however. I got molegrips on and managed to get a tiny bit of movement in the stud. With that, I swung to build up momentum, a similar motion to using a ratchet in a confined space. With every swing it was turning the stud just a tiny bit.

Eventually I got it out, along with most of the thread. This is going to hold me up as I need to save up and buy a decent quality tap to tap a new thread now.

I also decided to drill some new holes for the adapter plate, so that I could put the turbo on straight. Now the adapter plate is wonky to compensate for the turbo mounting studs being wonky as a result of not having a straight flange to line up. A bit of a bodge I know but I have no choice!



Bloody thing looks ugly as anything now as well:



Hey at least the turbo is straight now!



Then decided to start work on the exhaust elbow adapter plate:



I decided to go for a 70mm/2 3/4th inch hole because I wanted to leave some leeway for error. Good thing I did decide to do that as well, not sure if it might be a tad too big still though? Reckon firegum might be able to seal it up?



The reason I haven't cut it in the middle was to reduce the amount of medal I will have to hack off to get it to fit.

Stupidly though I drilled holes for the blank off plate for the compressor housing in the plate that I was going to use for the exhaust elbow adapter. As it happens I didn't need to make a blank off plate for the compressor housing recirculation valve after all!

Find out why below:

This was my bodge to save money:

Thread a screw into the hole with threadlock and then use quick metal over the top of it:



Probably overkill, but there's no way that is gonna leak any boost!

Chuck some firegum on the comp housing and then stick the empty recirculation plate back on:



Lubricate the silicone seal with oil and then put it back onto the CHRA:



Then get the comp housing back on and it starts to look like a turbo again!

I had to cut a slot on the adapter plate to allow the wastegate arm to move freely. I am still not sure if there is enough clearance for the rod to move or not:



The arm has enough space but I won't know about the rod until I can get it all back together to mock it up. Well, that's it for now chaps! The amount of time and money I have put into this so far is astounding. Just hope it works when it goes on, but it all seems so far away! There are so many problems to sort out before it can get anywhere near ready to bolt on.

Next week I will order the taps and then I can get some progress on the exhaust elbow adapter plate.