Turbo Housing Mods. Up to 30 hp for free

In shis, episode 125 of powerTec 10, DV shows why internal wastgate turbos
are far less efficient at generating boost than regular turbo's with an independant waste gate. Using an ECOBOOST 2.3 MUSTANG as an example here the mods that can be done to make a stock turbo houseing far more efficient are shown. With a 2.3 ecoboost you can expect a 30 lbs-ft and 30 HP increase for a week ends work and 0$ expenditure.

[@ThomasGellos-e6v]

This is a particularly interesting presentation because I haven't seen anyone else lecturing and presenting the technique and explanations. Well done DV

[@bill2178]

gale banks?

[@bigboreracing356]

Gale Banks hated rolling coal.

[@NickGreiner1988]

​​@@bigboreracing356 I used to work with a guy that thought "rolling coal" was something you could buy... Like just a sack of coal, special coal called rolling coal that you could use to make your diesel truck blow lots of black smoke out the exhaust 1:06

[@bigboreracing356]

@@NickGreiner1988 😆🤣😆

[@ronniejarvis2679]

You can gain a lot of insight by using a thermal camera while the turbo is still on the car and looking for hot spots on the turbo

[@phosion]

especially if you take into consideration the thickness of the material at the spot and the correlation of the area to the incoming flow angle etc

[@ThomasGellos-e6v]

@@phosion but I think the 30 hp claim was for a high boost eco engine. So a ten percent increase

[@matthewpatton5398]

​@@ThomasGellos-e6v who is going to waste time chiseling away for maybe 10pct when I can just buy a bigger turbo? Life is too short to screw around making things pretty for unimportant gains. Nobody is impressed by 10pct.

[@rockets4kids]

@@ThomasGellos-e6v I want to believe, but I also want to see data...

[@phosion]

I kinda knew already, but it does make a lot more sense now that the internal waste gate is kind of right in the middle of the most complex flow change in the turbo-motor, why someone wouldnt address this is questionable.

[@ElvinLeadfoot]

Dr. David! 30hp to the wheels is a lot Sir:) That’s all the power that’s needed to propel the car at cruise speed:)

[@bigboreracing356]

Guys married to whales will disagree.

[@theblackhand6485]

@Mr. Vizard: All well done. Thank you. But,...but next time please show is your used burrs and grinding tools. And of course picture from before and after. And may be showing the job in a moving angle to absolutely make us clear how to DIY. Thank you.

[@rolandtamaccio3285]

DV , glad you finally got a real pointer , lol ,,, ! ,,, btw , been looking for 40 plus years for these turbo mods , and this is the first mods I have seen ,,, !

[@Low760]

It's not that hard to open up a turbine housing and the wastegate?

[@Levibetz]

Interesting stuff, it'd be really great to see a before and after datalog with exhaust pressure traces. Makes me want to run out to the garage and throw the burr at all my turbos. I did have a cheap ebay turbo on a Subaru that wouldn't regulate boost at all, with the flap wide open it'd drive to 15psi of boost. I ported the wastegate area to blend the turn off to the gate and got it to gate down nicely to 8psi of boost. I have the inputs to add an exhaust pressure sensor, it'd be interesting to just touch up that discharge area into the turbine and see if I can measure a before and after change in backpressure/boost ratio.

[@СергейРакитянский-д6у]

Super video. Thank you David !

[@grapeknutz]

What you did is called commonsense cleansing, Thank you!

[@NotSure723]

Great episode!

[@richardscott8186]

Thank you David!!

[@rheidtech]

Love it Mr V. 👍🎩

[@donaldhalls2189]

This is the first tubo changes, ive seen, thanks for sharing, all the best to you and your loved ones

[@JohnAllen-b7l]

Thanks for the education.

[@scottsutherland7426]

David, you’re the man. Thanks for everything!

[@stigastondogg730]

Hello Great video as always May I ask - when you talk about exhaust back pressure, are you referring to pressure in the exhaust manifold feeding into the turbine housing? I didn’t quite catch that detail so I didn’t follow the reasoning around the 2:1 ratio and its impact on engine power. Thanks

[@Fk8td]

I don’t recommend removing exhaust outlet material in 2.3 eco boost. It’s very thin to begin with. That will never hold welding an exhaust port it will crack over time no matter what unless your not making any decent power. Not to mention the differential in exhaust flow between cylinders 2,3 and 1,4. I port headifolds and split headifolds. I doubt these mods on that size turbo will amount to 30 hp. Adding wastegate flow doesn’t add power at all. It helps control boost. You want as much as possible to go through the turbine with as little wastegate as possible while getting into the best areas of the compressor map. It’s also dependent on cams, displacement, and head flow to begin with.

[@enginedoc5988]

Agree with your statement about wall thickness. Do you think those are designed to fail on purpose? I was doing 2.0 st head that cracked in exhaust channel. Seems stupid to me to see exhaust manifold molded with cylinder head. Ive seen many overheated heads and very rarely cracked, I believe due to turbo glowing heat directly influencing aluminum head instead of iron manifold. But modifying and smoothing out wastegate should increase flow I think.

[@timtaylor6147]

Nothing to do with the video However I must say I'm impressed with the performance of the oil extreme additive Good shtuff -Yaa ! I've recommended it and showed evidence of it's action In a 5.3 Chevy with 3185xx miles that got a cam and valve springs at 270xxx miles Have been using Rotella but with the additive I have 10 psi more oil pressure overall and very noticeable lack of by products in the oil I do not run a pcv Amazingly even before using the product this engine produces virtually no oil vapor from the crankcase vents from the cover breather hoses that are merely laying in the engine bay on the inner wheel well Amazing The cam is 228 /230 duration on a 585 lift with 108 icl Rest is stock just the afore mentioned valve spring upgrade Tha PAC 1218

[@ElvinLeadfoot]

We know you have all the experience and behind the scenes gossip too Sir:) Tell us about your dealings with Offenhauser throughout your career:)

[@mattmorrison6958]

It looks like there was a lot of opportunity for improvement with the internal wastegate flapper impeding on turbine outlet flow on top of the usual issue of the wastegated flow disrupting the turbine outlet flow and ultimately the pressure ratio across the turbine. Really interesting with the ragged ledge there and sharp turn required! Looking at some of the divided turbine housings here, most don't have as sharp of a transition or edge

[@mattmorrison6958]

Forgot to mention, TiAL makes some really clever vband internally wastegated turbine housings. Not of use in this case, but you still may find their approach with an inconel sleeve around the outlet that forces the wastegated exhaust flow to re-join the main exhaust flow in a more laminar fashion. It's hard to find photos but we have some up on our website if curious

[@lukesimeon5756]

Great info DV

[@bigboreracing356]

The easiest way to go quicker is increase power to weight ratio by removing as much weight that does not hurt saftey or does not make power. Now your 30hp increase mods to the turbo perform more efficiently

[@ElvinLeadfoot]

King David:) I made a call to Offenhauser:) Inquiring about intake manifolds for Ford 4.6 2V and also 5.4’s An aluminum intake that will be comparable or exceeding the Mustang / Crown Vic factory plastic intake manifolds. Dr. David can you do a video on Offenhauser port o Sonic’s ???

[@dylanarnold4487]

Great vidja 🤙🏼

[@AdamOpheim]

Have you looked into a simple boost activated cutout for the downpipe? would keep the nice quiet factory exhaust note, then open on command when you wanted. I have a 2 way vac solenoid on mine so I can turn it on/off as well.

[@rickrack78]

# 1 👍🏻!

[@bill2178]

id just pick the right turbo to begin with but if your using stock turbos i guess this is worthwhile

[@russellbroadwell]

Your work looks amazing but without the test to back up your estimate, it could be called BS?

[@matthewpatton5398]

The dyno results belong attached to this vid. Breaking them into multiple just wastes everybody's time. If youre machining then show some live vid of some if the operations.

[@JC-gw3yo]

Thanks for all your effort on this Ford engine, but I just can't get as excited about it as the 2.3 Lima (Pinto) engine. Ford has gone really cheap on the engine as the exhaust manifold is built into the head. Hard to much mods here

[@witcher71]

Honda too

[@rocketsurgeon11]

While I absolutely agree that exhaust backpressure is the absolute enemy of a turbocharged engine, only the porting around the wastegate flapper and the matching of the ports to the turbine I feel are truly beneficial here. I think it is very important to highlight that the clearances in the housing to the wheels are VERY important and should NOT be altered unless you know EXACTLY what you are doing. Smoothing out that rough nozzle may improve flow, but if a person goes overboard it will reduce the velocity at which the gasses enter the turbine and will alter the turbo's response. Now, it's hard to say whether that will be a good change or not without testing. The important thing to remember is that it WILL change. As for the amount of recovered power without the addition of the larger downpipe, I am going to have to see that proven to me. I don't think these mods are worth 30whp. The majority of any power increase here will be from the downpipe.

[@billbraski2175]

I never watched the whole video. But did David show dyno results?

[@JohnShackelford-k2l]

Hello David Visard you remember racer Brown and I remember passing Ventura California. Nobody lives forever my memorial channel. Is gone but I still have my trucks. 1977 D200 366 1970 340 Offenhouser Holley 600 & B200 327 727 391rear. You can remember.

[@ghj1502]

Hi legend, Do you recommend Hard chromed stem Stainless valves with integral cast iron guides? Im having a hard time finding answers to this

[@coyote_chaser]

I've also made (airflow) changes to my Ecoboost motor. And have created electronic (fuel/timing) tuning issues... Can you help me understand how and why the ECU program seems to hinder engine modification??

[@croomsracingengines9265]

How much does it cost to run my heads through the IOP program

[@davidreed6070]

DV am I thinking right that the more back pressure,then the less overlap your cam needs,or overlap can be detrimental.

[@chestrockwell8328]

pretty sure as a general rule your aim should be zero back pressure anywhere in the intake or exhaust pathway.

[@CapablePimento]

So the obvious question that comes to mind is how much more power (above porting) can be achieved by switching to an external waste gate arrangement? Or in other words, how much of that potential do you reclaim? At a guess anyway.

[@mattmorrison6958]

I think implementing it may be difficult. The VE/spool/response benefits of reducing blowdown interference in a divided turbo setup rely on keeping the paired cylinders from cross talking with the others, so you'd need 2x external wastegates (gets very expensive, not to mention how to plumb) unless you divided the passage all the way up to the valve like the internal configuration does (also expensive). Maybe not as much of a concern with the minimal valve overlap though, but still likely to affect low rpm/stalling against a converter if there is cross talk/interference. There can definitely be other benefits, but just some things that we've seen that are often overlooked with factory divided IWG setups when you try implementing an external wastegate.

[@CapablePimento]

@@mattmorrison6958 makes sense.

[@james10739]

I was just thinking about turbo porting if anyone did it and if it made much sense

[@bobgyetvai9444]

David does this turbo have a air knife useing atmosphereic on the inlet side ?? Also is there a danger of too thin where the exhaust enters the snails shell so to speak where you slightly rounded it by .020 thou ?? Ty .

[@mightyfinejonboy]

would be interesting to see if leaking waste gates makes a big difference and if is it a common issue?

[@bcbloc02]

Doubt it. When I was doing some wastegate mod testing I was trying to get a .70ar housing to have the fast spool but make the top end pressure like that of a .80housing. Somewhere in the process I actually knocked the wastegate linkage off so it was wide open and in my case I didn't even notice it in how it was driving besides that once my boost got up to about 10psi the boost was beating the drive about 2psi. Prior to that the .80 always had more boost than drive but the .70 was always about 1-1. That was before I ported and reground the entry to the wastegate though and I found the gate was highly ineffective. Anyway eventually after much work I did manage to drop 10psi off the drive on that .70 and got it to match the .80 for overall back pressure but with 300rpm faster spoolup.

[@georgem8200]

TurboDirect make a good internal wastegate housing's if need be.

[@DavidVizard]

George, Do you have a part # for such? DV

[@georgem8200]

No i don't sorry. I just watch their utube videos when they upload which is rare these days with how busy they are building a new turbo manufacturing company, and all the problems their having in South Africa. Their prices puts all other manufacturers to shame.Dont know if you have heard of them, not many have,but they are worth watching.All i can remember on one of their videos is they designed a more efficient internal wastegated housing. Many other designs they improved on.

[@joeinmi8671]

Probably picked up mpg too...

[@bcbloc02]

It will not because the wastegate is only open when very near wide open loads. At any sort of normal cruising level the gate never opens.

[@joeinmi8671]

@bcbloc02 did you watch the video or just trolling?

[@bcbloc02]

@@joeinmi8671 the slight smoothing of the turbine entry will probably help some but the biggest power gains from what I saw done here I think come from the wastegate porting. It would not surprise me if the wastegate flow work done here won’t drop peak drive pressure 5psi.

[@michaelhargarten5118]

How many hours were put into all the porting and polishing?

[@DavidVizard]

It's in there so maybe you were not listening! 10 -12 hours

[@twochaudiomg2578]

... I've been doing this mod for 15 years. I got the idea of doing my motor. I should have run around telling everyone. Also Who over products this show. ?? No need I get it. Only 1 time. Sign up. Join. Not more then 7 or 6 Music has no meaning. Also.

[@wrighty338]

not at all surprising from a poor mass production level casting

[@CapablePimento]

Makes performance affordable for the masses, so it’s hard to call it a bad thing. IMHO. Although Japanese bikes dont have that problem.