Borg Warner EFR Series Turbo's V 2.0

[burn4005]

Also I ALWAYS use inconel bolts on the turbo flange.

[fatz]

Mom flange

[burn4005]

And Nord lock washers

[RICE RACING]

Here is a graphic example of the problems associated, it starts at the divider (where there is lack of clamping) and this diminishes over time significantly as this part of the manifold distorts and falls away so to speak, then its a slippery slope to turbo hell.

Ironically its more of a problem in road cars that run all the time at 1.000 Lambda and non optimized ignition settings, remember 98% of the time in a street car literally is spent here, and EGT can get very high.

The secret is run the car with a bit of excess fuel here to cool the exhaust and you will increase durability 10 fold.

 

[RICE RACING]

It not an issue of bolt clamp loss rather the material distorts (on the manifold) and the turbine housing to a lesser degree, then its game over. I put above a worst case scenario and simple color chart shows that on the flat flange area the temps you can use an aviation product (I have worked with it to 750 deg C) on outer of flange!) typically this never gets over 550 deg C as its transferring allot of heat by that time to the surrounding engine bay air.

The whole problem though starts at the center divider where there is no/little chance for heat transfer and its more RAPE than Mr Fritzle family fun times.

[Piggaz]

@sneakey pete. How many kms did the gasket do mate?

[Piggaz]

double post.

[mr_rbman]

16 hours ago, sneakey pete said:

Welp....

 

f**k.

 

 

 

Seems like the gasket has gone through or at least into the inlet to the turbine. Not yet removed manifold but i'm expecting to find chunks of gasket sitting in it.

What are my options now?

 

damn dude, you're really not having much luck with this engine/turbo combo

[sneakey pete]

Yeah its been a struggle. Has been in all of 12 months and 6-7000km and 2 track days.

 

I do wonder if bolts loosening have accelerated the process. Previous gasket i took off (after probably only 2000km) looked perfectly fine. Pretty sure this only blew out at the 2 sessions i got in at QR. The missing side of the gasket was on the looser side (nuts on studs instead of bolts).

Also I wonder if it was something with the tune also that may have not helped, unfortnatly my logging wasn't setup properly so I don't really have any useful info. Cruise wise EGT's aren't really that high for my setup currently as there hasn't been any setup completed on a wideband cruise, so thats probably not going to be it.

 

[RICE RACING]

Were nuts/bolts loose (on that side) as result of gasket missing?

Either way end result is homo :(

[Buraz]

[img]http://cdn.sau.com.au/monthly_2018_09/IMG_0009.thumb.jpg.4fdf4843f28279d641774cbbcfc8cb6e.jpg[/img]

 

Street driven Rotary, bit of half throttle boost gets this hot. My gasket fell apart too!! Now it makes sense what RICE said, egt’s get really high just cruising, because it doesn’t as hot when you’re trashing it.

 

[fatz]

You guys need a 6boob with a extra thick flange

 

i just happen to have one for sale

[RICE RACING]

1 hour ago, Buraz said:

 

 

Street driven Rotary, bit of half throttle boost gets this hot. My gasket fell apart too!! Now it makes sense what RICE said, egt’s get really high just cruising, because it doesn’t as hot when you’re trashing it.

 

Yeah been around them too long (since 1995) first T04 set up. My current combo is a BW369SXE and Tial V'Band single entry housing, no gaskets or dividers to get chewed, have a great pic of one housing where the whole center divider was eroded away from thermal fatigue... split pulse is a nice idea but shite in practice I found.

[Buraz]

Yeah been around them too long (since 1995) first T04 set up. My current combo is a BW369SXE and Tial V'Band single entry housing, no gaskets or dividers to get chewed, have a great pic of one housing where the whole center divider was eroded away from thermal fatigue... split pulse is a nice idea but shite in practice I found.

I’m actually going to a Borgy369SXE soon, Precision is getting tired and rear end is only .84 which is a bit small for a bridgey. I’ll look into the V Band option if that’s possible.

[RICE RACING]

I have a spare (Turbo, Tial housing + Tial 60mm gate) all new, if you are interested :) pm me.

[RICE RACING]

Here is some tests of a new set of EGT probes before going out to a customer.

You can reference these to the color chart I posted, dark orange at the open junction.

[sneakey pete]

Who's the cheapest seller at the moment, since BW doesn't seem to sell any parts to fix these with?

[burn4005]

Sparesbox have 20% off on eBay all the time but I'm not sure they actually can get their hands on them/have stock

[sneakey pete]

2980 on ebay without specials, best of the bunch. Have found one for 2350 out of the states, but that's before shipping gst customs etc.

[iruvyouskyrine]

5 hours ago, burn4005 said:

Sparesbox have 20% off on eBay all the time but I'm not sure they actually can get their hands on them/have stock

Do yourself a favour and don't use sparesbox.

I waited 10 months for mine to arrive and it was always coming 'next week'. Even getting my money back was a pain.