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Old 03-25-2012, 09:03 PM   #1
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Ported the 6cm2 turbine housing

Recently I was youtube stumbling as I call it, and i came across some porting videos and got to thinking it may be beneficial to do the same with the TD04 I have sitting above my desk, so the past weekend I went home gathered up some supplies and got to work! Results are not to bad, they could be better, the dremel kept dying and the bits I had didn't work to great


Before


After!


Yes I know, I got a little carried away on that top corner.....

Here are some more pics!
Enjoy
Ported turbine side pictures by Tap804 - Photobucket
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Old 03-26-2012, 04:16 AM   #2
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Plan on doing the exhaust manifold to match!
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Old 03-26-2012, 05:01 AM   #3
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And find some carbide bits, it will rip right through it.
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Old 03-26-2012, 05:09 AM   #4
 
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+1 on the carbide bits. Definitely the way to go....
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Old 03-26-2012, 11:25 AM   #5
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Definitely going to match to the manifold! That will have to wait until I get closer to the swap, with school and other things i'm way to busy to be down a car, i may even go to a junkyard and grab a spare,
Question though. With the carbide bits.. single cut, dual cut whats the difference? how much material is removed and the cut?

Thanks guys.
Tyler
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97 coupe, BBS Steinmetz 15t, braum seats, 93 aero, 630cc's b234i cams, ported EVERYTHING, slipping clutch 16psi made 256hp 263 tq
"stock with bolt ons"
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Old 03-26-2012, 05:59 PM   #6
 
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Single cut is a single spiral. Dual cut is a spiral cut with a different spiral cut at an angle to it.

When you open up the manifold, go back to the turbo housing to open it slightly larger than the manifold port so that there's a lip. A couple of old-school characters said this is a trick to reduce the effect of reversion.
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Old 03-27-2012, 07:28 AM   #7
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I was curious about how much if any benefit there was from porting the hot side. I am rebuilding my motor and figured I'd port and port match the exhaust side while I had things torn apart.
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Old 03-27-2012, 08:50 PM   #8
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I know it helps the flow, reduces the carbon build up, as for power increase i doubt it will add much, more noticeable power will be in the higher numbers.
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Exhaust gasses go in, Witchcraft happens.
97 coupe, BBS Steinmetz 15t, braum seats, 93 aero, 630cc's b234i cams, ported EVERYTHING, slipping clutch 16psi made 256hp 263 tq
"stock with bolt ons"
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Old 03-27-2012, 09:13 PM   #9
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I'd imagine the increase in flow will assist in lowering EGTs. Probably a good idea for anyone upgrading to 18 or 19t wheel.
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Old 03-28-2012, 10:59 AM   #10
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very cool, i don't think this is necessary though even with an 18t or 19t turbine..

that's why we go with the 6cm housing in the 1st place for the lower egts, i guess it'll give you more confidence from aggressive driving/pulls under hard boost.

but from what i understand the 6cm is enough.

what are the final dimensions of the housing ?
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Old 03-28-2012, 11:06 AM   #11
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^^^ This. The bottleneck is not in the manifold but the housing itself.
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Old 03-28-2012, 01:15 PM   #12
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The mounting flange isn't the only thing I worked on, there was a small ridge right by the waste gate that i worked down.



after


I was hesitant at first to take this out, thinking like a truck gets better gas mileage with the tailgate up, but i took it out anyways.

any opinions on this?
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Exhaust gasses go in, Witchcraft happens.
97 coupe, BBS Steinmetz 15t, braum seats, 93 aero, 630cc's b234i cams, ported EVERYTHING, slipping clutch 16psi made 256hp 263 tq
"stock with bolt ons"
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Old 03-28-2012, 01:20 PM   #13
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I'm thinking too much work for no quantifiable gains.


Full disclosure as a hypocrite:I ported my 5cm td04 and exhaust manifold last summer when I installed because I had one hand and new dremel and was bored as hell.
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Old 07-27-2012, 11:02 AM   #14
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Quote:
Originally Posted by Sleepy7666 View Post
I'm thinking too much work for no quantifiable gains.


Full disclosure as a hypocrite:I ported my 5cm td04 and exhaust manifold last summer when I installed because I had one hand and new dremel and was bored as hell.
While i was at school the turbo sat on top of my desk, i wanted to do something, stumbled upon that and It was a done deal if it helped any i would be happy, but i simply did it becasue of bordem.
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Old 07-27-2012, 11:10 AM   #15
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Update.

I brought the turbo to a welder, and had him weld a 3in vband on both the dp and the turbo,

I cut the stock flange off and machiened the inside out. Doesnt feel as restricted when i get into higher boost like the T25 did. I can kinda tell in the exhaust note more when it the WG opens

Final vs the vband laying over top.






After it being welded, before machining




Final result, welds on both the inside and out, i dont want that sucker comin off.
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Old 07-27-2012, 02:16 PM   #16
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wow. that looks nice. and way easier to put together.
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Old 07-29-2012, 01:56 AM   #17
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Quote:
Originally Posted by turbojohnny View Post
wow. that looks nice. and way easier to put together.
Oh worlds easier, you can loosen the clamp just enough so the lock nut stays on, but is big enough for both pipes to sit in the groove, and then crank it down. soooo much easier than the three bolts
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