controlling boost...(WASTEGATE NOW FITTED photos online)

[Fin[uk]]

Hi All,

I have searched for this but can not find a deffinate answer...

Last weekend I sorted the old turbo manifol out and bolted it back on the engine... Then just as I was about to fit the stock turbo back on....the sodding Wastegate disc/valve fell out :rant: Oooooh JOY

So as most have done (and i have a free flowing exhaust with Electric Dump/Cutout on the down pipe) Ive got an External Waste gate (HKS style 50mm adjustable unit) to fit on the crossover pipe and Im welding up the disc on the turbo.

Now Im looking at how to control the boost level....

I have an Ultimate Chip kit sat here waiting to go on the TY.

Can I use the stock ECU control system, or do I need to buy a manual boost controler and set the boost to the same level as the Ultimate chip program Im going to be using

thanks
Fin

 

[Tooky]

Re: controlling boost......Mmmmm

Re: controlling boost......Mmmmm

From what I know, the Ultimate built-in electronic boost control is only calibrated for the stock turbo/wastegate, and it works notoriously poorly (although some have lucked out with good control from it). So your best bet is to use the manual boost controller, that's what I do. Although theoretically if you are very skilled with ECM recalibration, you could potentially recalibrate the Ultimate chip boost control tables to work with your external wastegate, food for thought.

 

[ghettosled]

Re: controlling boost......Mmmmm

Re: controlling boost......Mmmmm

use a stand alone boost controler and set the chip to max boost since it will have no effect on the actual boost the truck makes.. The stock ecu is intended to work only with internal or single port wastegate designs, and on heavy duty actuators or most of the bolt on turbo upgrades with larger wastegates it seems to work decent about 50% of the time.

 

[Fin[uk]]

Re: controlling boost......Mmmmm

Re: controlling boost......Mmmmm

Thanks guys

 

[Fin[uk]]

Re: controlling boost......Mmmmm

Re: controlling boost......Mmmmm

Ive welded in the 50mm HKS style waste gate on the crossover today.... Will get pictures up once I have made the exit pipe tomorrow

 

[Fin[uk]]

Re: controlling boost...(WASTEGATE NOW FITTED photos online)

a bit more metal can not hurt... :lol:

As you can see Ive had to squeeze the little waste gate exit pipe so it just fits between the charge cooler rad and the front 1 1/2" sway bar

Wonder what it will sound like..... :???:

 

[ghettosled]

Re: controlling boost...(WASTEGATE NOW FITTED photos online)

that thing must barely clear the lower cche..

the pipe will definately quiet it down and sound less like a huge exhaust leak.

 

[Ian Turgeon]

Re: controlling boost...(WASTEGATE NOW FITTED photos online)

The best manual controller I found was simply a compressor air regulator from home depot, I'd still be using it if I handn't switched to an electronic unit. The only down side is that air temperature (summer / winter) will make a difference in how much boost it will build, so it needed to be adjusted slightly when temps changed.

 

[Fin[uk]]

Re: controlling boost...(WASTEGATE NOW FITTED photos online)

Its a tight fit for sure, but it does fit with a little bit of clearance each side (I test fitted everything....well not sure about the bottom fan surround but it dont matter too much if that is not fitted). Had to squash the 2" tube down to about an 1" hence Ive expanded it wider

I didnt like the look of the stock cross over tube, so went with a cut open 45 deg bend this gives much more area to weld to the old cross over

fingures crossed its all goes back together

 

[Fin[uk]]

Re: controlling boost...(WASTEGATE NOW FITTED photos online)

Yep was given a manual boost controler the other day so with a bit of luck it will all work when back together

 

[Ian Turgeon]

Re: controlling boost...(WASTEGATE NOW FITTED photos online)

I punched a hole in my lower cche with my wastegate... took a little while but enough rocking back and forth from boost launches finally liberated all the water from the intercooler. I ended up putting spacers between the cche and the frame to lower it away from the wastegate. Worked wonders, so if your cutting it close, its easy enough to do.

 

[Fin[uk]]

Re: controlling boost...(WASTEGATE NOW FITTED photos online)

Im fitting it back together today so will see if I can make a bit more room.

The gate its self is about an inch off the back of the cche, the exit pipe is close to the bottom metal mount of the intercooler rad