Well if you are reading this you know exactly what I am talking about... if not it is a O2 dump fabbed up by R/TErnie and it was a bartered trade for some materials that i bought him. On to the project.... It started off good, drained radiator easy right! (End night 1)...(Day 2) Drained oil... didn't pay attention and when it started dripping it missed the pan, so I got to clean up an oily mess yeah! Pulled the radiator no problem! Dropped the DP, pulled the turbo... no problems! We then go to prep the new 9 turbo going on the car and realize that there is a broken stud and a stripped hole... WTF! Mind you the hot side had been polished already! So we now have 2 10.5 hotsides, one polished and one stock.... We decide to try and remove a stud from the stock hotside to put into the polished one... good idea right? Broke Le Stud on the good stock housing trying to remove it for the tattered polished one... FAIL! So now we have 2 housings, both with broken studs. Now the fun part... from 10 am till 8 pm (10 hours) we wrestle with getting a damn broken stud out of the stock housing (remember all we had to do was put this on) SUCCESS!!! Porting ensued for another 2 hours (End night 2)...(Day 3) We feel confident today! Nothing could be as bad as yeaterday right... Jesus christ! Well lets see... we now know why everyone uses the two 2.5 holed O2 housing flanges... it was a complete struggle on the flapper side "shrinking" the tight radius tubing from almost 4" down to 2" in 2 cheater bends... our first try= FAIL... second try looks pretty good. Mind you we were in it for the fabrication sake of things so we did it like we set out to do. We side cut the dump tube and welded it to the outside of the DP and tear dropped it at the bottom.(SICK) All the fab for the dump took about 8 hours total, and 80% of the time was spent fabbing up the dump side. Then we welded up the exhaust with a v-band and flex section, put everything back together and viola the underbraces won't fit my new DP... We are going to make some aluminum CNCd spacers to drop the brace down next weekend... Ahhh... everything is in place finally, put oil and coolant back in and started buttoning everything up. DONE... pull the engine fuse so we can prime the turbo, put the fuse back in and fire it up (3:45 am last night) go for a ride and the turbo seems to spool a tad quicker, then did a low boost (16 psi) pull to see what I am in for... at first I was like WTF... Then I was like crap dude this is loud as a *****. Went back and dropped Ernie off and prepared for the 1 hour drive back home. Hit boostorz a few times on the interstate and the dump sounds pretty mean but like I said previously hella loud! Get home at 5:15 am sleep for 1 hour and then head to work... I am tired as a SOB!

CLIFFS... Put on 9 turbo, broke bolt on hotside, tried removing bolt from another good hotside=2 bad hotsides, turns into a nightmare, fab is a nightmare, dump is loud as crap, worked on it for 3 days and didn't finish till 4 am last night, drove 1 hour home and slept for 1 hour and went to work tired as a SOB. dump is loud as hell!

 

gah! What a nightmare! But persistance pays off. How did you end up getting the broken stud out?

 

We chopped it off clean, drilled through it which took for evar! Tried an easy out and it broke, so we just heated it with the tig welder and basically melted the stud out of the hole... threads were pretty much intact and we just retapped the hole...

 

pics before i call you a lier




Glad you guys finally got it done!

 

We were so irritated about the whole process we didn't take pics of it out of the car... I will get some of it installed in the car tonight for you guys to check out....

 

Updated... added pics

 

Sick!! now we need some video/sound clips.

 

wow..nice job guys!

 

Thanks to R/TErnie as always!

 

After talking with Eric today we are gonna pull it out again this weekend and tweak it a little more, as the flexpipe hangs a bit low for that whole "warm and fuzzy" and I am scared I am gonna catch it on something. We will have it out of the car again this weekend, so I will get some better pics of everything. We also need to go back and pulse weld everything to make it look bling and also port the internal portion. I still need to go log it, take a couple degrees of timing out and add some fuel so I can actually get on it at high boost and see how it feels!

 

You Guys Rock...It looks like a Killer Design, and the fabrication/welding are top notch. A big double to both of you. I know this is not an easy task but you guys did it. Def subscribed for more pics and details.....

 

Looks good guys. Nice job!

Todd B.
Pres.
EPM (a division of No Limit Industries)

 

Nice!!! I have another 10.5 with four bad threads if you'd like one more!!! Bet the neighbors are liken you even more now huh?

 

Well guys a little update... I went out logging/tuning last night and I am getting really really bad boost creep... like 30 psi boost creep! The wastegate hold fine at like 15psi (low boost) and then at like 5000 it rockets up to 30 psi and doesn't wanna stop. I have to diagnose the problem tonight, and will be running a small vaccum line from the wastegate nipple to the turbo inlet nipple to see if it is a wastegate problem, as I suspect there may be a problem with the wastegate as it was used and the nipple was a bit bent when I received it . If that is unsuccessful then I will take the arm completely off the flapper and see if I still creep... if I do then i have bigger problems and will have to go back to the drawing board...

 

I've been down that road before. You are on the right track, check the WGA then move to the Flapper arm, and so on. Hopefully its something simple like a boost leak. If that's the case then it solenoid time. Keep us posted, keep on it you are almost there with it...