curtis
Well-known member
Ok many of you have done it. Taken the wastegate flapper pull it shut and weld the flapper to the housing, Others remove the flapper and place the gate out the side by the o2 housing. So today I was fabing up my turbo and getting it ready to sell a local guy, he's buying it for his 1st gen and bought a bep dsm manifold which has the wastegate flange cast to the number one runner. I was planing on just welding up the flapper but the bullseye housings have a large hole and leaves the inlet of the turbine with a large area for turbulence etc.
So I took a piece of copper sheet and cut a 2 x 3 square out and radiused it and formed it to fit down in the scroll and block the hole then I went to the side and started filling it in with the mig welder. I skipped back and forth and it was finally filled then I removed the copper it was stuck in a few places and had to rip it out with a pair of vice grips then I took a carbide burr and cleaned it up then a cartridge roll, I had a few spots that I missed so I welded it from the turbine side and then went back over it with a burr and then the rolls again. Turned out perfect. I had heard about backing stuff with copper but never tried it till today.
Here's a picture
So I took a piece of copper sheet and cut a 2 x 3 square out and radiused it and formed it to fit down in the scroll and block the hole then I went to the side and started filling it in with the mig welder. I skipped back and forth and it was finally filled then I removed the copper it was stuck in a few places and had to rip it out with a pair of vice grips then I took a carbide burr and cleaned it up then a cartridge roll, I had a few spots that I missed so I welded it from the turbine side and then went back over it with a burr and then the rolls again. Turned out perfect. I had heard about backing stuff with copper but never tried it till today.
Here's a picture