1.6TD Megabuild

[cyrus #1]

I've got a couple of small updates.  I got a buddy from our local VW forum to wash some of my stuff.  Thanks Capilon!

There's some funny looking green stuff that was hiding under 1/2" of oily diesel muck. :lol:



The head still looks kind of haggard in this picture but it's actually pretty clean.  The inside of the ports look like it just came out of the factory.  I'm amazed at how effective these hot water+soap parts washers really are.



Now, on to tonight's million dollar question.  You may remember my "Is this turbo scrap?" thread.  http://www.vwdiesel.net/phpBB/viewtopic.php?t=16529&highlight=turbo+scrap Well, tonight I decided to dissect a bit further and all seemed to go well until I got to the wastegate.  It would appear that there should be four studs/nuts holding on the plate over the back of the wastegate.  I have two studs and two that have been welded.  Is this correct, or has it been bastardized?  See below for pictures.







My guess is that someone has broken two of the studs and just welded it on.  I do need to get it apart so I can inspect the inside for cracks.  :?

[Smokey Eddy]

uhhh could just say "maybe there are cracks maybe there isn't"
and if willing, try it with that part if it works well it works and if it doesnt it doesnt?
Are there fins missing on that impeller?

[dillenger1]

You should re -stud the wastegate block,dont want no creepy boost leaks.Impeller looks good.

[Smokey Eddy]

Impeller looks good.

Thanks, i dunno what it's s'posed to look like.

[cyrus #1]

I will re-stud the wastegate cover.  I drilled the welds and the studs spun right out with a pair of vice grips.    Does anybody know if this wastegate can come apart?  I'd like to lap the valve seeing as I've already come this far.  I'm going to take the housing to work tomorrow and clean it up in the varsol tank.  There does appear to be quite a bit of cracking.

I searched and apparently there should be a large snap ring type thing holding the top of the wastegate can together.  Mine appears to be crimped together though.  :?

[riddleyo]

Looks like a great project!

[mattbondy]

This is going back a bit in this post but I always thought it would be pretty cool to mount a head on a nice piece of stained hardwood and put it up on the wall somewhere. Have a little plate with the year and model, perhaps the odometer reading.

[cyrus #1]

Well, the compressor housing cleaned up quite nicely in the varsol tank.  Unfortunately, that's about all the good turbo news I have.  



As you can see in the following pictures the turbine housing is littered with cracks.  I imagine this is what happens if you hop in the car in the middle of winter and immediately floor it up to 140, every day for 20 years. :evil:















Those cracks by the wastegate are the ones that bother me.  There is a huge crack that runs from the turbine inlet all the way to where the exhaust gasses enter the waste gate.  I can stick my finger nail in it.  I did try the solvent test.  The solvent poured out the wastegate cracks as fast as I could put it in.

I'm not feeling real confident in running this turbo now.  So, it looks as if I'm in the market for a new turbo now.  I'll be looking for something a bit more modern.  Ball bearing or VNT, here we come!  :twisted:

[cyrus #1]

Looks like a great project!

Thanks.  I've been inspired by all the great builds on here.  Hopefully there will be many more to come.

This is going back a bit in this post but I always thought it would be pretty cool to mount a head on a nice piece of stained hardwood and put it up on the wall somewhere. Have a little plate with the year and model, perhaps the odometer reading.

I like to do stuff like that with broken parts.  :twisted:  If I ever snap a timing belt, the bent valves will be made into a keychain.

[Smokey Eddy]

those cracks look awefully familiar to a post a month or two ago...