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Thread: Internal turbo wastegate movement / clearance

  1. #1
    Is a Chief Engine Builder wilbo666's Avatar
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    Default Internal turbo wastegate movement / clearance

    I've got some dump flanges for turbos (massive kudos to MrDOHC ! ). The flanges are designed (by me) to split the wastegate and main flow.

    I'm curious as to the range of movement the wastegate flap encounters in operation!

    Depending on how much movement the wastegate flap needs my design may cause the wastegate flap to hit my flange...

    It isn't a drama for me to modify the flange / wastegate outlet; and I suspect that going on the side of caution is what I should do, but I am still interested the answer!

    Pics to show what I mean!







    Cheers
    Wilbo

  2. #2
    DIY Bloodline Domestic Engineer Talasas's Avatar
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    Default Re: Internal turbo wastegate movement / clearance

    It's doubtful that is will move that far, the stock wastegate on my CT9 only opens about 45 degrees at most, probably less. I did the same with my downpipe flange, and then put the wastegate actuator on and it didn't even come close.

    That being said you should test it with your actuator if you can, but I still doubt it will open quite so far.
    "In the beginning, the universe was created. This has made a lot of people angry and has widely been regarded as a bad move." -HHGG

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    Is a Chief Engine Builder wilbo666's Avatar
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    Default Re: Internal turbo wastegate movement / clearance

    The thing is the exahust gases will push on the flap with a large amount of force which I can't really simulate out of the car.

    Simply applying pressure to the actuator won't really show what the movement will be in use (no exhaust gas pressure)...

    I did look at the actuator, and try and determine what the maximum extended length could be. Not knowing the internal design tho it looks like there might be enough movement to extend past the angle where the flange would block it...

    Cheers
    Wilbo

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    AVGAS DRINKING Carport Converter 30psi 4agte's Avatar
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    Default Re: Internal turbo wastegate movement / clearance

    I tend to agree with Talasas. There isnt much movement in them. The wastegate actuator rarely opens fully ( totaly extended) on any setup.

    Example : My old turbo would only push the gate open approx 45deg at over 9000 rpm.

    If you run a slightly larger pipe than the wastegate flap it should have plenty ov clearence for the flap to open all the way if needed any way
    Last edited by 30psi 4agte; 28-03-2007 at 11:07 AM.

  5. #5
    DIY Bloodline Domestic Engineer Talasas's Avatar
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    Default Re: Internal turbo wastegate movement / clearance

    The thing is the exahust gases will push on the flap with a large amount of force which I can't really simulate out of the car.
    The point you're missing is once it's attached to the actuator it can only move as far as the actuator allows it. You can simulate this by hooking up the actuator arm and pulling it out as far as it goes by hand. I figure won't open more than that.
    "In the beginning, the universe was created. This has made a lot of people angry and has widely been regarded as a bad move." -HHGG

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    Senior ****** Carport Converter Sam_Q's Avatar
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    Default Re: Internal turbo wastegate movement / clearance

    a bit of a side topic but have thought about making and installing a divider so that the exhuast wheel gases don't go near the wastegate?

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    Is a Chief Engine Builder wilbo666's Avatar
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    Default Re: Internal turbo wastegate movement / clearance

    Quote Originally Posted by talasas
    The point you're missing is once it's attached to the actuator it can only move as far as the actuator allows it. You can simulate this by hooking up the actuator arm and pulling it out as far as it goes by hand. I figure won't open more than that.
    OK, I wasn't sure if pulling on the actuator fully would damage it, but now I think about it can't see that it would

    Ta!

    I'll give that a go and see what the outcome is!

    Quote Originally Posted by Sam_Q
    a bit of a side topic but have thought about making and installing a divider so that the exhuast wheel gases don't go near the wastegate?
    Yep I'm already planning to do that

    Cheers
    Wilbo

  8. #8
    Junior Member Domestic Engineer RobertoX's Avatar
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    Default Re: Internal turbo wastegate movement / clearance

    then you can have the wastegate pipe just venting straight down.. screamer for extra noise

  9. #9
    Senior ****** Carport Converter Sam_Q's Avatar
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    Default Re: Internal turbo wastegate movement / clearance

    Quote Originally Posted by RobertoX
    then you can have the wastegate pipe just venting straight down.. screamer for extra noise
    thats not quite what I had in mind but yeah you could do that

    apparently not having the wastegate air and exhuast air join for atleast 30cm is the optimum

  10. #10
    Is a Chief Engine Builder wilbo666's Avatar
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    Default Re: Internal turbo wastegate movement / clearance

    Pic is fully extended (looks about 45deg ish)

    You guys were well right



    If I was making them again I would have moved the wastegate circle closer to the top to allow a smoother flow for the wastegate gases...live and learn I guess

    Cheers
    Wilbo

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    AVGAS DRINKING Carport Converter 30psi 4agte's Avatar
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    Default Re: Internal turbo wastegate movement / clearance

    Cant you just grind it out with a die grinder ?

  12. #12
    Is a Chief Engine Builder wilbo666's Avatar
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    Default Re: Internal turbo wastegate movement / clearance

    Quote Originally Posted by 30psi 4agte
    Cant you just grind it out with a die grinder ?
    Yes I could, but if I had of placed the hole further to the top when I designed then I wouldn't need to

    Also if I grind it out to an oval as opposed to a circle it will make the connecting of the wastegate pipe slightly more difficult.

    Cheers
    Wilbo

  13. #13
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    Default Re: Internal turbo wastegate movement / clearance

    oval the inside edge then.

    leave the pipe side of the plate round
    hello

  14. #14
    Junior Member Too Much Toyota
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    Default Re: Internal turbo wastegate movement / clearance

    jeez - wilbo's small dremel will die carving out that plate? Or is that steel reasonably easy to grind?

    And do we get to call Phil Doctor Flange when we see him next?
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  15. #15
    Is a Chief Engine Builder wilbo666's Avatar
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    Default Re: Internal turbo wastegate movement / clearance

    Quote Originally Posted by thechuckster
    jeez - wilbo's small dremel will die carving out that plate? Or is that steel reasonably easy to grind?
    dremel would die...

    But new favourite tool = power file

    Quote Originally Posted by thechuckster
    And do we get to call Phil Doctor Flange when we see him next?
    Indeed!

    Cheers
    Wilbo

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