Modifying an Audi Wastegate. PICS FIXED!!! 17 pics
08-01-2005, 11:22 AM
#1
3.0 BAR
Thread Starter
Join Date: Sep 2003
Posts: 3,751
Modifying an Audi Wastegate. PICS FIXED!!! 17 pics
Well many people are wanting to run these but at 14.5psi and non-adjustable it is not very feasble on a Honda. Well I redid this writeup so the pics are up to date. I'm not sure if it was the same method as Shorty's but this is what I came up with. I do not know the range of PSI it is now but from the lowest setting the is next to no pre-load on the spring and you can open the wastegate with your pinky finger. It can probably be adjusted to have a higher then 14.5PSI rating as the bolt you replace is longer then the Stock one.
First Pull the top of the wastegate off. there is 6 8mm nuts. Once apart it should look like this.
Secure the Hat in a Vice for ease and Grab an Allen Wrench
Next using an Allen Wrench remove the Little Spring Seat be turning the bolt. Mine was tight and had to use some leverage, but it should come.
Next go back to the hat and using a drill bit just smaller then the thread, drill through the hat. Be careful not to hit the threads, you need those!
Turn the hat over and using a larger bit drill out the little brown peice of metal you see here. If you use a large enough bit eventually the metal will break free and come out. Mine Did.
Now return to the spring seat, Cut off the extra boss on the bottom to shorten it. I use an 4.5" grinder. I tried my band saw, but it is Harden metal, so if all you have is a hack saw, you'l be there for a while.
Return to the hat and using a Large Drill bit, Drill off the Thread Boss to make it shorter, By the time I stopped, I have about 5-6 Threads left.
I did't have a large enough drill bit so I used a die grinder to flaten the boss and clean it up a little.
Next Get a longer bolt. Try to find the longer one that you can that still has full depth of threads. You also need a Nut and Washer. Bolt size is a M12x1.25
Side the bolt through the spring seat and place the washer on like so.
I tack welder the washer to the bolt. This way the sping seat can still float and spin during adjustments.
Thread the spring seat through the bottom of the hat.
Thread the nut that is going to serve as your lock nut from the top.
Reassemble the hat to the wastegat and reinstall the 6 8mm nuts.
Next using a cut-off wheel I put a small notch in the bolt.
The notch is for using a flat head to adjust the spring preload, and thus boost.
There you have it. Again I have not tested this theory,and wont be till next seaon probably, but I see no reason why this would not work, It acts the same way as most name brand waste gates.
Good luck and I hope this helps some people out.
First Pull the top of the wastegate off. there is 6 8mm nuts. Once apart it should look like this.
Secure the Hat in a Vice for ease and Grab an Allen Wrench
Next using an Allen Wrench remove the Little Spring Seat be turning the bolt. Mine was tight and had to use some leverage, but it should come.
Next go back to the hat and using a drill bit just smaller then the thread, drill through the hat. Be careful not to hit the threads, you need those!
Turn the hat over and using a larger bit drill out the little brown peice of metal you see here. If you use a large enough bit eventually the metal will break free and come out. Mine Did.
Now return to the spring seat, Cut off the extra boss on the bottom to shorten it. I use an 4.5" grinder. I tried my band saw, but it is Harden metal, so if all you have is a hack saw, you'l be there for a while.
Return to the hat and using a Large Drill bit, Drill off the Thread Boss to make it shorter, By the time I stopped, I have about 5-6 Threads left.
I did't have a large enough drill bit so I used a die grinder to flaten the boss and clean it up a little.
Next Get a longer bolt. Try to find the longer one that you can that still has full depth of threads. You also need a Nut and Washer. Bolt size is a M12x1.25
Side the bolt through the spring seat and place the washer on like so.
I tack welder the washer to the bolt. This way the sping seat can still float and spin during adjustments.
Thread the spring seat through the bottom of the hat.
Thread the nut that is going to serve as your lock nut from the top.
Reassemble the hat to the wastegat and reinstall the 6 8mm nuts.
Next using a cut-off wheel I put a small notch in the bolt.
The notch is for using a flat head to adjust the spring preload, and thus boost.
There you have it. Again I have not tested this theory,and wont be till next seaon probably, but I see no reason why this would not work, It acts the same way as most name brand waste gates.
Good luck and I hope this helps some people out.
08-01-2005, 11:38 AM
#2
1.0 BAR
Join Date: Apr 2004
Posts: 240
Re: Modifying an Audi Wastegate. New Write Up, 17 pics
Just mounted a audi gate onto my HF manifold and have it dumping externally.
It seems to only want to go upto 4psi stock (strange when i expected 14.5psi or so
). I ran it off the side port with that huge banjo bolt.
With boost controller inline it goes higher without issue.
Runs like this..... compressor housing..... purge cut solenoid..... audi WG
-------......stock WG.
It seems to only want to go upto 4psi stock (strange when i expected 14.5psi or so
). I ran it off the side port with that huge banjo bolt.With boost controller inline it goes higher without issue.
Runs like this..... compressor housing..... purge cut solenoid..... audi WG
-------......stock WG.
08-01-2005, 11:48 AM
#3
3.0 BAR
Thread Starter
Join Date: Sep 2003
Posts: 3,751
Re: Modifying an Audi Wastegate. New Write Up, 17 pics
Ya, You must have something off. They are 14.psi from factory.
UPDATE ON PSI RANGE:
I don't know the max, but again I know I can take it higher then the 14.5psi be preloading the spring.
As for the Min, Using a Digital Pressure, air press regualtor and a compressor, I was able to pull the Compressor down to a lowest setting of 4.0psi and the wastegate would open fully no problem. I probably could go lower yet, But Why?
UPDATE ON PSI RANGE:
I don't know the max, but again I know I can take it higher then the 14.5psi be preloading the spring.
As for the Min, Using a Digital Pressure, air press regualtor and a compressor, I was able to pull the Compressor down to a lowest setting of 4.0psi and the wastegate would open fully no problem. I probably could go lower yet, But Why?
08-02-2005, 05:48 PM
#10
1.0 BAR
Join Date: Apr 2004
Posts: 240
Re: Modifying an Audi Wastegate. New Write Up, 17 pics
Originally Posted by splitime
Originally Posted by baldur
Why would anyone ever want to run less than 14psi boost?
But mine ran 4psi Maybe mine was modified... anyways, boost controller on it and its all happy.
