2nd Generation Specific (1986-1992) 1986-1992 Discussion including performance modifications and technical support sections.

s5 wastegate porting...

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Old 06-14-04 | 07:28 PM
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From: Coquitlam BC Canada
s5 wastegate porting...

Just wondering, whats the diameter of all 3 of the holes on ur wastegates. Or what do u reccommend? And, is it alright to weld on a washer or do i need a valve? thanks a lot

matt
Old 06-14-04 | 07:33 PM
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Aaron Cake's Avatar
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You mean two holes, right?

Port them out to the maximum size of the flapper door. If you are brave, go several MM past that. If you now need to raise your boost, use a boost controller to do so.
Old 06-14-04 | 08:26 PM
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http://fc3spro.com/TECH/HOWTO/KWG/kwg.html


-Ted
Old 06-14-04 | 10:09 PM
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ya well none of that says how big to make the holes or how big the stock holes are? I need to tell a shop how big the stock holes are and how big i want them. The shop is about an hour drive away so it would be much easier to tell him all the required information and get a quote, rather than to drive down there and show him the wastegate, only to find out his quote is bull ****.

thanks
Old 06-15-04 | 12:07 AM
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why not grab a ruler?
Old 06-15-04 | 12:12 AM
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Originally posted by bigtymer
ya well none of that says how big to make the holes or how big the stock holes are? I need to tell a shop how big the stock holes are and how big i want them. The shop is about an hour drive away so it would be much easier to tell him all the required information and get a quote, rather than to drive down there and show him the wastegate, only to find out his quote is bull ****.

thanks
why not buy a dremel and do it yourself, that something simple enough for you to do

good luck
Old 06-15-04 | 02:02 AM
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ask and you shall receive

before


after
Old 06-15-04 | 02:45 AM
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SO WILL i need to weld a new flapper on or will the stock one be fine?
Old 06-15-04 | 06:21 AM
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I ported the holes & kept the stock pucks.
I also trimmed about 2mm off the back side of the flapper so it could swing open more before hitting the back plate.
Before: 6-9-11-12-12
After: 5-6-6-6-6
(Stock intake & gutted cats)
Old 06-15-04 | 09:48 AM
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You CAN port the hole bigger then the flapper door. Just make sure that the door cannot get stuck in the hole. Then simply use a boost controller (preferably an electronic unit, but manual will of course work) to raise your boost to the level you want.

With the hole larger then the flapper, you will lose a small amount of low end boost. But with an upgraded exhaust and intake, it will be unnoticable.
Old 06-15-04 | 03:50 PM
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You don't need to go bigger.
With the holes ported to the size in my pics, the car does solid 2.5psi (yes, two point five psi) with an H-trim compressor upgrade.


-Ted
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