Wastegate Elbow to Manifold Bolts - D-series.org

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Old 03-07-2011, 07:09 PM   #1 (permalink)
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Default Wastegate Elbow to Manifold Bolts

Being i have a low hood clearance i have to run an elbow from the manifold over to the wastegate. At first i was using class 8.8 bolts(m8x1.25) to hold the elbow on the manifold and they kept breaking so i went up to class 10.9 bolts of the same size. After a few days they broke off as well. So out of frustration I drilled and tapped the manifold and flange to accommodate 7/16-14 Grade 8 bolts Now after 3 days they have broke.


Any ideas on what to do now? Or maybe even some bolts or studs that wont break after 3 days....
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Old 03-07-2011, 07:19 PM   #2 (permalink)
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Fastenal has some Caterpillar grade bolts. They are supposed to be a good bit stronger than grade 8.

Here is a chart that shows the different grades and strength.

Hex Bolt Identification Guide - Engineers Edge

Do you have a flex pipe or your down pipe?
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Old 03-07-2011, 07:29 PM   #3 (permalink)
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How is your wastegate pipe routed? Got a pic of the setup? Sounds like you have other problems than bolt strength. Quality Grade 8 bolts are good shit, chinese hardware is a different story.
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Old 03-07-2011, 07:50 PM   #4 (permalink)
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i wanna see how yours look like i have a hood clearance problem too it made a crack on my hook with the cast iron mani and a tial replica wastegate.
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Old 03-07-2011, 08:15 PM   #5 (permalink)
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I always ran an elbow (I think its still around somewhere), and never had an issue. One time I snapped one, and just started using longer bolts. Never had an issue again.
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Old 03-07-2011, 08:17 PM   #6 (permalink)
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Quote:
Originally Posted by tonyquach01 View Post
i wanna see how yours look like i have a hood clearance problem too it made a crack on my hook with the cast iron mani and a tial replica wastegate.
Hope this helps.

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Old 03-08-2011, 10:35 AM   #7 (permalink)
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How about afix a bracket from say the motor to that elbow to help brace it?
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Old 03-08-2011, 12:25 PM   #8 (permalink)
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Quote:
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How about afix a bracket from say the motor to that elbow to help brace it?
i agree, some kind of bracket coming off maybe the valve cover or head that bolts to the WG or elbow i think would help a lot.
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Old 03-08-2011, 02:09 PM   #9 (permalink)
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where did you get that elbow?
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Old 03-08-2011, 05:14 PM   #10 (permalink)
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How would i go about welding steel to cast iron? Could that be done with a flux core mig or would i need something different?
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Old 03-09-2011, 04:27 PM   #11 (permalink)
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My elbow is custom made. Here are some pics..









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Old 03-09-2011, 04:30 PM   #12 (permalink)
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Do you run a dump tube? If not, just fab up a bracket that runs from one of the P/S or A/C bolt holes in the block onto one of the bolt holes of the WG exit flange.
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Old 03-09-2011, 05:38 PM   #13 (permalink)
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Yes i do i had it off in the pics though.
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Old 03-14-2011, 12:31 PM   #14 (permalink)
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I ended up tig welding the elbow to the manifold and so far soo good. Now just to figure out why my car has a sudden leaning out when in boost.
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