Symptoms:
Running on a flat highway, empty at 70mph (D250 Reg Cab 5spd 3.54's) I'm running 2psi boost and 650-degree (POST TURBO) EGT's. Under full throttle I only see 30psi max boost, and it spools SLOWWWW. Before the rag met the turbo, the stock H1C/18.5 would turn 5-7psi on the freeway, at 600 degrees, and would spool very quickly.

Mods:
4" Exhaust, POD's, Pump Bump, HX35W/12cm2, BHAF.


Details:
Sucked rag through the stock H1C/18.5cm2 turbo
Replaced turbo with HX35W/12cm2 - Ran Rough
Cleaned Intercooler - Ran Better but not right
Replaced Intercooler - Runs Great but no power
Pressure tested Intercooler/Couplings/Turbo/Intake - no leaks

I talked to Piers at the Texas Rally and he told me to pressure test the system, and I'd probably find a leak....well I didn't, so now I'm lost.

Tomorrow I'll be shortening my downpipe for a better fit, and while I'm doing that I'll be welding up the wastegate.

???

 

tighten up the wastegate arm and make sure it's sealed up good... you should have to pull the arm 1/4 or more to get it over the flapper post

Forrest

 

See how it is after the wastegate is welded shut. Just make sure its fully welded shut. The first time I did mine after it cooled I shone a flashlight inside and could see a sliver of light thru it. Fortunatly I only put a small tack on it so it was easy to grind off and redo. The second time I held it shut with vice-grips and it worked fine.

I only see about 32psi max with my stock turbo with a 12cm2 housing. It spools pretty good and runs about 300-400f post turbo on highway. Have to work it really hard to get it to 900F. Usually the coolant temp is more of an issue at that point.

 

Wonder if you'd be happier with a bigger turbo housing for the freeway.

 

I actually ditched the 16 for the 12 and haven't looked back. I tow a Jeep and camper with it, 6000lbs combined and it tows great.

 

Well, I'm down home for a few days, I'm going to weld the valve up solid and see what happens here in a few hours, I'll let you guys know what happens...