Hey everyone, I'm in the process of installing the old style BR cast 35R kit (the one with the 38mm wastegate) and I've run into a problem that's really getting on my nerves. I don't have the right bolts to make it work. Sounds stupid, but let me explain...

The o2 housing has threaded bolt holes that are a 1/2-20 thread size. However, the problem that I'm running into is I can't find ones SHORT enough. The hotside of the turbo is MAYBE a 1/2 inch (if that) above the flange of the o2 housing. I've tried just about every auto parts store, hardware store, and home improvement store in about a 30 mile radius of my house. The closest thing I have found is a 1/2-20 drain plug. It's short enough, but the hex head is monsterous.

I have a Cobb DP, which has the bent lip around the flange. I'm thinking if I throw some heat to it, I can bend that lip down and make it work. Any thoughts on this?

I called Buschur the other day, and spoke to Jarrod. After explaining my problem to him, I got the impression that he thought I was asking stupid questions. After he told me to go to the hardware store, and I explained I've checked everywhere, I asked him if he could send me the bolts. $19 later, he sent me bolts that were about 2 inches long with washers and nuts. I'm not sure if the design changed in the later model of kit, but these were completely wrong. Maybe he was just having a rough day (which I can totally understand), but I explained which kit I had, and my problem but still received the wrong stuff. Jarrod is known for his excellent customer service and knowledge, so I don't know what happened. I'll call back tomorrow, as I only got the bolts today when I got home (after BR's closing time), and see what he says.

Sorry for the long, ranting post. I've just been dicking with this for a while now, and it's really getting frustrating that the only thing that is holding me up are these two damn bolts. I really want to leave feedback for the seller, and get the car up and running, but I don't want to half-*** anything. If anyone has any advice, please feel free to add.

Thanks guys.

 

Can you put the head of the bolt on the other side and put a lock nut on the dp side ?

 

I was going to suggest the same thing! I had an issus when I bolted up my MAP dump houseing and the bolt and spring supply was WAYYYY to short so I re-used one of the stock bolt&springs the other (being as it was designed for the supplyed bolt in the kit) the thred pattern was off a little I guess. I limped it to a local muffler shop that does all my welding and had them look at it. They did just what was said above^^^^ he snuged up the other bolt&spring and ran a bolt with a lock washer on the other side and its been great ever since not a hint of an exhaust leak. if there is room i would give this a try

 

type this # 91251A965 into the search box here http://www.mcmaster.com/#

 

just use a grinder and cut the bolt shorter. I do it all the time. Its quick and eash and only takes a few mins at most.

 

^^^^+1 cut the bolts man make your life easier.

 

Why don't you just use some lock washers and/or flat washers to take up the space?

 

This is how I originally had it. You'd think that would be the "correct" way to do it. However, the head of the bolt is still too big and rubs the hotside.

I was trying to avoid doing this, because of the threads in the o2 housing bolt holes. If I was just threading on a nut, that's what I'd do. However, I don't want to jack up those threads in the o2 housing.

You're my freaking hero. This is exactly what I need, thank you so much. Hopefully I can find them locally so I don't have to wait another week of downtime.

 

Mcmaster is suprisingly fast, they have same day shipping/delivery for most of NJ. I'd assume they have your bolts by tomorrow if you ordered today.

 

Just got done submitting my order. That's good to hear though, thanks!

 

The flange on that Cobb downpipe looks like sh*tty thin press bent metal. The BR downpipe has a nice thick flange on it. So the bolts that Jarrod sent you are probably correct as they would be long enough to go through the thick dp and turbo flanges.

 

I have the same kit bro. Your bolts are installed wrong. lol

 

Sorry for the confusion and Jarrod's attitude.

Please send the bolts back but the problem is the downpipe from what I see. Our downpipes use a flange that is nearly a 1/2" thick, that downpipe you have uses a paper thin flange.

We'll give you the money back on the kit, including shipping. Just call us first and get an RA#, let whomever you talk to know I said to refund 100% of the money.

Sorry about the confusion.

 

https://secure.buschurracing.com/cat...5c1e0c4b9ccb6f

This is the kit that Jarrod sent me bolts for. I wish I had this o2 housing. I'd make my life WAY easier. I have a bolted on o2 housing, not a V-Band and the flange is closer to the hotside. (As can be seen in my pics.) I can't even get my little finger in between the flange and the hotside of the turbo.

LOL, no you don't. You probably have the kit which I linked above. In which case, the bolts Jarrod sent me would work and if I HAD that kit, I WOULD be installing them wrong.

Unless the previous owner altered the o2 housing in someway, which he says he didn't, you CAN'T install the bolts backwards. I linked this thread to Jarrod, and the previous owner. Maybe they can chime in and shed some light on this.

 

Awesome of David Buschur to stand behind both his product and the service his shop provides. If I remember correctly that kit, when bought from Buschur, includes the down pipe as well so this would not have been an issue. I highly recommend using the Buschur down pipe with his kits as that is what was engineered together to work the best. I run the Buschur Cast 3065 kit and am very happy with it.

Josh