Actuator Troubles (check My Pic)

[islade]

Only reason I'm reluctant to go external gate is the cost.

I'll pull turbo off one more time, return it to Mr Turbo and get them to check out the wastegate again, because they had already removed and refitted the wastegate once.

If not, i'll evaluate the external gate VS new turbo thing

[l0WRB]

oh ok.

yeh i bought a 50mm gate off net for around $200, then my mech took turbo off modified it all and put it all back together for around $250 i think...

from what i heard gavin wood isnt cheap so yeh u mite be better going garrett turbo gt35r or something... price u pay 2 live somewhere flash and get fancy ppl 2 do work that other guys can do for 1/4 the price..

[mad082]

ok after paying a bit more attention to the picture this time, i would say that the design of the turbo is the problem. the fact that both the turbine gases and the wastegate gases have to go out such a small hole, and the wastegate gases come out of the wastegate and basically hit a wall and have to change direction and then are getting slowed down by the gases coming out of the turbine.

the best analogy would be to imagine you are driving down a road. lets say it has 4 lanes and all the cars are going at 40km/h because it is extremely busy (peak hour) and it drops down to 3 lanes up ahead for 100m then goes into 5 lanes and the traffic there is moving much faster because of extra lanes and the fact that now people aren't trying to merge in and make people have to slow down. so basically from the moment people enter the 3 lane section they can start speeding up again. now imagine that there is a road off to the left that branches off just before the 3 lane section and joins back up with the main section a bit further down. now in the case of an external gate or an internal gate that uses the same sort of rear housing as the stock turbo, this road would join back up after the 3 lane section has finished so they can basically merge into 1 of the lanes without having to really slow down much as there is plenty of space. however in the case of your turbo, this road that branches off and goes to a sharp turn that makes you slow down, and then joins back up in the middle of the 3 lane section at 90 degrees to the road. now you have to find gaps to fit into and the amount of cars being able to take that route is much lower, meaning more cars have to take the main route.

you really need a split dump pipe setup for it.

looking at a pic of a kkr650, they look to have something you can take out to get at the wastegate. i would look at getting a pipe made up to go into there and then into your dump pipe. i would say that doing that would solve your issues. as for how much it costs, i couldn't say but i would guess it would be cheaper than going external gate by the time you buy a wastegate then get the manifold setup for it.

[islade]

Hey guys, just giving an update

I've pulled the turbo off again. Going to drop it in today.

With my highly technical 'wiggling wastegate with actuator disconnected' testing methadology, I've discovered the most of the time it opens and closes fine.

Sometimes when it goes to close, the bottom of the wastegate flap gets caught on the inside of the wastegate hole, meaning the gate can never close all the way.

No matter how hard you try to close it, it won't close then, as it's jammed. If you open it up and close it again, your OK, but obviously my actuator wouldn't be doing that

I'll let you guys know how it goes

[Adriano]

Thats because the bushing in the housing moves which is what locates the flapper.