Big Blue24

Well, it's not much, but I can now easily pass a quarter through the wastegate passage. I took it up from the stock 7/8"=22.22mm to 27mm which is 1.06". I also smoothed out the 90*corner so that exhaust can flow more directly into the wastegate passage. I'm sure that it will make a touch more turbulence in the main flow going through the turbine but I figure that the 9cm housing will spool a lot faster than stock anyway.

99globalwarmer

i would keep grinding, try and match the gasket and you could probably enlarge that wastegate hole a little more but it looks good the waste gate should open easier now and at lower boost. looks sweet

ScottGregory

Looks good. Curious as to how much overlap on the wastegate seal? I left 0.12 on mine when I ported on my s300

5.9Excursion

If you are going thru that work, port match the exhaust manifold to the head, and then open the exhaust housing up to match the manifold. Your picture shows where the gasket seals it up. It doesn't take long...

Big Blue24

Yeah, I was gonna wait till I pulled the stock turbo off my truck to see the gasket overlap/ opening of the stock manifold. You can only open up the stock manifold so much and then I was gonna match the gasket to the largest useable stock opening and then use the gasket to determine how much to grind on this one.

According to my measurements, the stock puck is 32mm so that leaves 2.5-3 mm of overlap or .01"

Not much room to open it up any more.

pearlbronze2500

Can I ask why you would go to that much trouble for a stock 3rd Gen turbo? Is it going on the 2nd Gen truck in your sig? That 9cm exhaust housing should make for some very unreasonably high EGT's!

HOHN

That's what I did with my turbo and manifold. I port matched them both to the turbine inlet gasket, then I ported the manifold runners to match the exhaust port in the engine.

That turbo should spool really quick, but the single-scroll housing is less efficient and drive pressure well get pretty high real fast.

I'd keep it under 35psi if I were you.

JMO

Big Blue24

It is just a fun experiment. My budget is 500 bucks. The only real hard part is modifying my setup in such a way that if this fails, I can still go back to stock HX-35.

I have a question for you all, member Cbrahs gave me a downpipe, but I still do not have a clamp. The stock downpipe from 04.5-06 appears to be 409 stainless. Can I weld 409 to the cast elbow? Or do I need to braze it? My buddy is a great welder but don't want to overuse him if I can just braze it myself. Bronze flux coated has a working temp 1350*-1600* so it should never see enough heat to melt.

Hohn, when you opened up your stock gate, do you recall how big the stock wastegate passage/ puck is on an HX-35 12cm? Reason I ask is this turbo has a smaller turbine wheel as well. I can't imagine how some CR guys can push this up to 500+ HP with seemingly less flow than a stock HX-35. It has 12 blades on the turbine and appears to be 60mm exducer with maybe 65-70mm inducer/bigger side. The compressor is definitely 60mm inducer.

Big Blue24

Hey Justin, are you going to enter a burnout competition with your rear skins before you buy some new meat? If you do, remember to air them down a bit, high pressure is what causes them to blow, not burning them down past the steel belts.

You know, all the heat from the burnout on top of 55-60 psi gets 100+psi in a hurry.

Ph4tty

Is that the "stock turbo" you're going to wring 500 hp out of?

haloman

and with those Jammer 5's. Go for it, we all love to see carnage.

HOHN

I didn't measure my HX35 puck, but by calibrated eyeball I'd say it was maybe an inch and an eighth. I could have opened up my WG port a little more, but I was concerned with the puck sealing properly, so I didn't push the limits on puck coverage. I had a good 1/8" overlap around the circumference.

For a single HX35 this is plenty of gate. As a top charger for twins, it's not even close to being enough.

I'm not sure if your talking to me about burnouts, but I don't do burnouts. I generally don't abuse my truck. No revved up 3rd gear launches as such for me.

But I have been known to shift aggressively at full fuel a time or two..
hundred

JDGnut

Didn't the later 3rd gens go back to a 12cm housing???

Big Blue24

I wasn't aware of that. If that is the case, I might have to just sell this turbo and get an even later 3rd gen. I thought all 04.5-early07 were identical.

WVAussie

I'm sure this isn't the turbo to use if your shooting for 500 hp but here are plenty of 3rd gen trucks running HP well above stock on this turbo. Why is that the opinion is that you can't make the same power level in a 2nd gen with this turbo that the 3rd gens do? EGT's and drive pressure are pointed out as being problems but why more with a 2nd gen than the 3rds. I'm no expert for sure but only using inducer size when comparing a compressor wheel doesn't really give the whole picture, does it? And just looking at a hx35 and a hy35 on the bench it's hard to see how the hy doesn't flow better. There is way less less restriction apart from the smaller exhaust housing. What is the optimum drive pressure?