Hi all,

I want to port my wastegate hole and make a new flapper and was wondering if it is made out of any special grade of steel to cope with the heat?

Can I buy a bigger flapper anywhere?

I've done a search and I've found that the general consensis is to enlarge the hole 6mm.

Headsex has an excellent thread on it but the pics are missing!

Anyone else got any tips?

Thanks

Rob

Flapper can be had here its an AVO one Click ME think the APS ones were 321 stainless. If you need pictures let me know I can email then to you.

Pretty sure GCG do change over units.

Frank

ive got a tip for you... you dont need to change the flapper valve.... just enlarge the hole so the stock flapper JUST covers it. with about 1mm clearance all round. Then you need to bur over the arm end to hold the flapper disc tighter with less play so it doesnt bind or jam when it closes... been done many times with great success.... 400rwkw no worries

Flapper can be had here its an AVO one Click ME think the APS ones were 321 stainless. If you need pictures let me know I can email then to you.

Pretty sure GCG do change over units.

Frank

Thanks Frank, good find there.

I phoned GCG and it'll cost me $450 for the exhaust housing and a 12 psi actuator.

I'm a tightass and want to get out of it as cheaply as I can.

ive got a tip for you... you dont need to change the flapper valve.... just enlarge the hole so the stock flapper JUST covers it. with about 1mm clearance all round. Then you need to bur over the arm end to hold the flapper disc tighter with less play so it doesnt bind or jam when it closes... been done many times with great success.... 400rwkw no worries

Thanks for the tip Groper.

I will try that first and if it doesn't work I'll just get the new flapper and fit it.

Edited December 17, 200718 yr by Dagabond

I ended up getting a 37mm flapper and a 12psi actuator from GCG in Sydney.

I ported the wastegate hole to just under 32mm and fitted the flapper.

I originally wasn't going to get a new flapper, but I ported the hole too big and the original one got stuck and wouldn't fully close.

Flapper cost was $62.50. Considering it was around $300 exchange and $900 outright, it worked out to be a good deal.

With the money I saved I now have to get a 4" dump pipe and a new cat.

Where does it end????

The first photo is the difference in the flapper sizes

Second is the original size hole

Third is the ported hole with new flapper

Thanks for posting back and letting us know how you went Green, good read.

Good job

Thanks for posting back and letting us know how you went Green, good read.

No worries.

I can also add I was a bit worried that I had ported it too big (I've heard of bigger).

When the original flapper wouldn't close properly I thought , no drama I'll just get a bigger one.

Problem was before I welded it I couldn't get it to close properly either.

I was pretty stressed and rang up about if it needs to be loose (Yes it does, the flapper is originally very loose) and asked about a new modified housing ($900).

I decided I've got nothing to loose by welding it any way so I stuck a couple of brass shims between the flapper and the arm to get the play, tack welded it and knocked the collar down slightly tighter until it would close properly. It ended up with plenty of play to allow for expansion and apparantly it also spins around as well (not at speed, just the seating position).

In the end it was worth it.

Edited January 11, 200818 yr by GreenXR6T

Good job

Thanks Frank