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930s rule the wasteland
 
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Question wastegate rebuild

Bringing wastegate to replace diaphram and put 1.2 bar spring in. what am I getting into
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1980 930 Turbo
1993 Corrado
1983 944
1984 944
2001 VW golf TDI
Old 12-09-2008, 05:04 PM
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It's very easy, but if you have a vice or clamps big enough to slowly open and close the top, you'll be in better shape. Check the valve and valve guide for wear while your at it.

1.2 bar? Are you set up for that fuel and I/C wise? What are your other mods?
Old 12-09-2008, 05:43 PM
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i just got my WUR back from Brian Leask ,set it up for all my mods k27 ,******** full bay intercooler,fuel enrichment system, removed injectors to flush with a bosch injector checker, adjusting valves ,installing new plugs,rebuilding wastegate, and disconnecting manual boost and putting back to stock. Brian recommended installing the Innovate in cockpit air/fuel guage.
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1980 930 Turbo
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Old 12-09-2008, 05:52 PM
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The A/F gauge is a must. To be honest, I wouldn't go past 1 bar. That's what I've used for years with a rev limiter set at 6400 rpm. Makes the engine last a lot longer.

Just my .02
Old 12-09-2008, 05:56 PM
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1.2bar with stock internals? Have you done anything to the engine to cope with this? You need an awful lot more than an intercooler and fuel enrichment, which K27 turbo are you using? And who advised you to fit a 1.2bar spring anyway? If you do have a build that will cope with 1.2bar you won't want to run it at 1.2bar all the time surely?
Old 12-09-2008, 06:01 PM
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I'll take it , no mine would boost to 2 bar but I never really tried to go past a bar. I feel safer putting the 1.2 in it and see how it does. I was checking into a infared co checker but the Innovate seems more practical and about the same amount of money.
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Old 12-09-2008, 06:02 PM
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Your 930 is set up to run 2.0bar
Old 12-09-2008, 06:05 PM
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what is the stock boost anyway? I bought the car already modified. Its wicked fast so I just want to tone it down where I'm not gonna grenade it. Really not feeling finding a case for this thing. I'll get the wastegate broken apart and see what they did to it. Like I said this thing will wind up to 2 bar and I havent blown it in 2 years. I'll let you know.
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Old 12-09-2008, 06:10 PM
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thats what the 2 gauges say
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Old 12-09-2008, 06:11 PM
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stock 1 in the tach and the 935 gauge
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Old 12-09-2008, 06:12 PM
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Factory is .8 bar.
Old 12-09-2008, 06:13 PM
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The stck gauge is very inaccurate. Is it a real 935 gauge? I believe they are inaccurate as well. A more modern NHS boost gauge would more accurate.

Quote:
stock 1 in the tach and the 935 gauge
Old 12-09-2008, 06:16 PM
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Anything over 1.0bar will require quite a bit of work to keep it together. To keep it together at 1.2bar would at least require stronger con rods and rod bolts, head studs and head sealing/flame rings. Then you would need good grade fuel and ideally twin plugs, at this point it is silly to keep the CIS system, you would junk this and go EFI. To go to 2.0bar you would need to have a magic wand, some magic beans and a magic carpet.

If your engine is stock internally do not take it above 1.0bar, definately get the Innovate LM1 or LM2 to help you dial in your adjustable WUR and also to keep an eye on your fuel regularly. It's good that you've got your injectors matched for flow as you'll be reading your AFR's from 1 sensor after the turbo, knowing you're getting equal flow is a good thing

Last edited by JBL930; 12-09-2008 at 06:33 PM..
Old 12-09-2008, 06:30 PM
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did the engine get enough fuel for running 2,0bar?
It must be crazy fast with this pressure...
Old 12-10-2008, 02:03 AM
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ok the spring is a 1 bar spring thats going in. i understand the one side of the diaphram is held in the cup by a 10 mm nut how do you seat the other side of the diaphram?
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Old 12-10-2008, 10:34 AM
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Could be a confusion of definition between measured boost and absolute pressure. Air pressure at sea level is 1bar. Some gages read in absolute which means 1 bar ambient + 1bar boost = 2bar.

Either way please do not use more than a 1.0bar spring, the stock air cooled 930 engines are not designed for it.
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Old 12-10-2008, 06:22 PM
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Quote:
Originally Posted by RarlyL8 View Post
Could be a confusion of definition between measured boost and absolute pressure. Air pressure at sea level is 1bar. Some gages read in absolute which means 1 bar ambient + 1bar boost = 2bar.

Either way please do not use more than a 1.0bar spring, the stock air cooled 930 engines are not designed for it.
Great point.
I like the VDO gage that reads -0,5 Vacuum to 1.5 bar boost for this reason and like to see the vacuum on th engine when running low load or cruising. The 2.0 bar gage is like having a 200mph speedo in a Toyota Corolla.
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Old 12-11-2008, 07:36 AM
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When I disassembled the wastegate I was more worried about getting shot in the head so I got ahead of myself. Just so I can sleep at nite can you verify that I did this right Almighty Porsche Gods. I removed the cup that holds the diaphram (10 mm nut w/ washer). Folded diaphram and put cup inside diaphram and tightend 10mm nut. Pulled lip of diaphram over wastegate housing . Put the shims on each side of spring and compressed and testsed. waste gate opens with compressed air and seems to be working ok. Does this sound rightbefore I install on car?
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Old 12-11-2008, 09:00 AM
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Sound right, but any pics?
Old 12-11-2008, 10:01 AM
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No pics, should of took as I disassembled then I wouldnt be writing this. Ill try it out and see what happens
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Old 12-11-2008, 10:25 AM
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