reh5108's 4 Banging SHITBOX tUrBo 4x4 Build

Interesting
What do you think the scouring could be from?
Was it a new or used turbo that you put in when you originally installed it?

 

It's was used but didn't have many miles. It's not terrible but it can be felt. Looking back at the last time I had it apart for a similar reason it looks very similar. After thinking about this all night I recall only filling oil to the dipstick to the halfway mark when I had the problem before.

I have everything to rebuild it with new bearings and I just ordered stepped ring seals. Hopefully those will help and draining half a quart of oil will help. There is quite a bit of crud around that seal to that could be causing issues as well.

 

Got the turbo rebuilt today. Installed some step ring seals to hopefully seal better. Also installed a 360° thrust bearing. The old bearings had some wear on them and there was some very fine metal fleks inside. Now I just need to figure out how to replace the studs on the exhaust housing. One snapped on removal and the threads on the other 4 are fubar. Hopefully they will willing come out with some heat to the housing.

 

What you are saying is that you need to fill the oil to the top dot on the dip stick.

Looks like better repair parts are going in than came out. Should extend the life to prevent repair for some length of time hopefully.

 

Pick up a little flux core welder from harbor freight I don't really have any steel around to test on but the little bit I have done I've been impressed.
Found some more cracks... Guess I'm going to have to pull the manifold off and once it's off I'll take it to work and NDT all of the welds and see if I find more before throwing it back on.

 

What kind of setup do you have for doing NDT, Ryan?

 

Pretty basic, just a magnetic probe and a particle solution. I did just realize the tubes are stainless so non ferrous but the welds are ferrous. Not sure how it's going to work out. We did just get a coil which will make things easier for a majority of the parts we need to shoot. It hasn't been set up yet though.

 

What were you welding with before?

 

That’s really interesting. My previous job was with a fairly big aerospace company and they had an pretty extensive NDT lab. Lots of x-rays (including a badass real-time x-ray), CT scanners, and I think they even had a scanning electron microscope. It’s definitely a cool field.

 

Which grade wire are you using to weld with?

 

My roommate in Colorado had a Miller with gas.

It is interesting but it gets to be pretty mundane with what we do with it. Here's a 1" bolt with a longitudinal crack almost the entire length. Cut it in half and it penetrated almost to the center of the bolt.

I don't know what the manifold was welded with. Not even sure what the welder I bought came with either. I'm know it's not what it should be.

 

Suppose I should find some stainless flux wire.


Broke 3 of the 4 studs I was trying to remove from the turbine housing. Time to drill and hopefully only chase threads.

 

Well fuck me. Just found the turbine housing is cracking.

 

Damn :/

wonder if too high of EGT's did that

 

This turbo is going to be the death of you.

 

Could be. I'd think I'd have engine damage in that case though.

It may very well be.

 

Well at least it was a used turbo that got you motivated to get things installed and running. Time for a better one?

 

This^^^ the hard part is done, swapping a new turbo is easy if funds allow

 

Not yet. Need to install an intercooler and figure out what I want to do for tuning be before I ruin a twin scroll, ball bearing turbo.

Ehh sorta, I wouldn't mind building my own manifold for twin scroll someday and I'm kind of locked in to the t3 with 5 bolt exhaust unless I want to fab another downpipe. Not that it's difficult just time consuming.

 

As long as you have oil, and possibly coolant, you wouldn't ruin a twin scroll or other turbo.