Last weekend I have been having some boost problems. Once minute 14 psi, the next minute I would only see 5 psi. I noticed the problem got worse after I drove around for a while and got everything nice and hot...
This weekend I pulled off the wastegate and took it apart to check it out. When I opened it I noticed the silicon diaphram was partially melted and slightly deformed. After looking over the entire setup I noticed that the top (aluminum housing) of the wastegate was literally touching one of the maniold runners. I am thinking that the aluminum conducted too much heat from the manifold which caused the diaphram to get too hot and melt. Here is a pic of the manifold and the wastegate mated together before I originally put it all in the car. Does anyone think the wastegate is mounted too close to the header? Is this what may have caused my problem, or is there something I am missing?

 

those tial aren't supposed to break under the heat i thought. maybe you got a defective one ?

 

Yea, I hear a lot about what certain products are "supposed" to do. I know it was not defective cause I took it apart and inspected it before I installed it and it looked fine.

 

that thing looks way too close for comfort. do you have another angle?

 

Wow ! That is way to close Josh. It needs some breathing room. I have never seen them made that close it usually sticks out behind the engine. I would have question that before I'd installed it.

Manny

 

Yeah, most setups I have seen have the wastegate back near the motor mounts. The diaphragms in the wastegates are the most delicate parts.

 

True but I was told that there have never been any problems with this setup with any other cars. Believe me, I questioned a lot of stuff.

 

This is what urks me, people claim Tial to have to best wastegates and blow off valves just because their friend had one and it worked. If thats the cause how come so many people are using the HKS wastegates and the turbosmart gates. Go with whats proven over what is said to be the best friggen wastegate. The fact is that the HKS and Greddy wastegates are the racers choice and thats for a reason.

 

I don't think this is a problem with the Tial WG, I think it is a problem with the manifold design. Don't you agree Greg? Silicon will melt if it gets hot enough regardless of which brand of WG it is used in.

 

It could have just been a fluke. Sometimes I've been the luck 1/1000 to get a defective product.

 

Where's enzo250?

 

 

Do they sell a replacement part?

 

I will call and find out moday. The problem is I need to find out how to prevent this from happening again.

 

I agree with the manifold design being not too thought through but I also think that unproved influences can lean someone towards a certain prodduct when there are tons of "race proven" products out there that we know will do that Job. Anyways, good luck with the car Josh, Im getting a mig welder in around 2 weeks so if you wanna stop by and try to redesign your turbo system thats fine

 

Get a TIG!

 

too expensive this one I found used for a good price

 

Sell that turbo TV and get a tig

 

This setup supposedly has been used by many with no problems. I don't know what you mean by "race proven". All the true racers out there usually build their own manifolds and I wouldn't neccessarily call a "kit" race proven. Marcus tells me he has build about 50 of these manifolds (he may have been exagerating). Is this not enough to call it "proven"? At what point is a maifold proven? Since I do not have any welding skills I had no choice but to find someone to build it for me. All I can do it take their word on their design and if they tell me it worked great in other cars then who am I to argue? I can't believe that building a manifold where the WG is touching the manifold is acceptable, especially when there is plenty of room to aim the WG an inch or two away from the manifold runner. Maybe others with this manifold have had similar problems as me but just didn't have the sense to speak up about it. I really find it hard to believe that my case is an isolated one.

 

50 of those manifolds yea right, How many people on this board have the Williams manifold. You and maybe a few other might be the only ones. I really doubt that the HKS techs or Trust techs would make a manifold that would place the wastegate so close to the runner. The new HKS FD manifold looks like a nice manifold and it would do the job. BTW, I never said Kits But I can honestly say that I dont think there is anything wrong with a turbo kit (other than price). I wouldnt do it but hey.....

 

You could always just get some piping and have a muffler shop extend the wastegate pipe. It won't look as nice as the rest of the manifold, but at least it will keep the wategate away from the heat. Just be lucky that the wastegate didn't open up completely when it failed.

 

yea, I just looked through the "post your single turbo" post and you and turbostreetfighter are the only ones that said that they were using the williams manifold.

 

I am just going by what marcus told me. Don't bash me about his claims. I am sure we are not the only two using his manifold. I have talked to one other person and seen pics of another. Just because they are not posted on the forum doesn't mean they don't exist.

I am kind of glad the WG didn't get stuck closed but it was really never stuck either way. It just gave inconsistent boost. I could get the dump pipe adjusted a little but it is currently plumbed into the DP and I would have to make some changes to that too.

 

yo man, noone is blasting you about anything, you get too defensive too quickly

 

I agree - keep the wastegate away from exhaust runners are much as possible.&nbsp It's a mechanical actuator with a silicon-reinforced (typically) diaphram inside.&nbsp I'm not too sure if this is your problem, cause if this diaphram got damage, you'd have problems with too much boost rather than too little boost.



-Ted