Ive always heard stories on Honda-Tech about wastegate vacuum lines popping off, bursting, or melting leaving the wastegate clueless as to how much boost the turbo is making. The turbo over boosts and destroys the engine, if your not careful.

This vacuum line is the most important line in a turbo car and is the most problematic at the same time. Like oil return lines that are close to very high temps, I thought it would be a good idea to convert this vacuum line to steel braided too.

This is a quick write up that a few people requested I post.

You'll need a 22" -3AN Steel Braided Line; measured from my compressor's vacuum port to the side of my TiAL 38mm wastegate. For a common setup using a Revhard/Drag/Inline Pro manifold this is a good length. If your using a different manifold or wastegate placement, you'll need to measure. I got my line from Stan (Flamenco-T) for $22.

Now heres was the hard part. TiAL wastgates come with two barbed banjo fittings for a vacuum source and boost controller. These fittings have to be replaced with something that can accommodate a -3AN line. The vacuum ports on Tial wastegates are 10mm x 1.0mm thread pitch. That is the size for the 35/38mm models, Im not sure about the bigger ones.

After much searching for the right fittings I ended up with a new banjo and matching banjo bolt. Metric banjo fittings with a -3AN inlet are hard to come by. Earl's Plumbing had what I needed.

<u>Earl's P/N</u> available from SummitRacing.com
997631 Banjo - 10mm core, .445" height, -3AN inlet $6.69
977517 Banjo Bolt - 10mm x 1.0mm thread (fine) $4.39 includes crush washers.



Now the only problem with the new banjo bolts is that they are too long. The threaded shank is 1" long. This is a problem because when threaded into the side of the wastegate port, it hits the wastegate diaphram. I called Earls, they do NOT make a shorter banjo bolt that is 10mm x 1.0mm thread. So I had a local shop take 1/4" off with their lathe and they didn't charge me. It only took 10 mins and I couldn't imagine anyone charging more than $5 to do this.

Thats the only part which makes this not a perfect turn-key solution. Stan may offer this as one of his kits in the future. He proposes using a 10mm to -3AN adapter than a 90* elbow. That would also work however the space between the wastegate and head is tight.

The port on the turbo compressor housing is 1/8" NPT. I used a 1/8" NPT 90* Elbo to -3AN on the turbo side. I got that fitting from Stan when I ordered my SS braided line.

Here's what it looks like when its done.




*Edited: Fixed picture links a year later


Modified by Muckman at 9:49 PM 5/6/2005

 

puurttyyy

 

nice work

 

That is a great write up, thanks for contributing it! I've added it to my ever growing list of things to do to my teg

 

While it's a nice idea using a banjo bolt and fitting, I'm curious why you didn't just use a 1/8" npt fitting to a -3 an 90 degree?? Wouldn't that be much simpler, and you don't have to worry about having crush washers? I thought about running braided line for the wastegate myself but I think it's just too overkill. As long as it's not too close to a heat source or rubbing against something and you have it attached properly, I don't think it's necessary. I mean hell, if it was actually a problem, factory turbo cars wouldn't be using rubber lines.

-Mike

 

I forgot to include the turbo side fitting above. I did use a 1/8" NPT to -3AN 90* fitting on that end.

It may be overkill but if you've ever had your vac line burst like mine did, caused by either heat and/or pressure. That was all the motivation I needed. And its only $30 in parts for peace of mind!

 

Awesome info!

 

Ive been wanting to do this also! nice job

 

is there a poin to that, other then to look nice?

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by bluep3 &raquo;</TD></TR><TR><TD CLASS="quote">is there a poin to that, other then to look nice? </TD></TR></TABLE>

zero chance of melting a vacum line or having one slip off....

 

Good job muckman.

 

overboost just = more power

writeup good, overboost bad, mmk?

 

very nice...

 

vacuum lines suck. I blew the vacuum line to my MAP sensor once. It blew off at 16psi at over 7000rpms in 3rd. Once the line blew - the map sensor read zero boost and my ecu stopped adding fuel. Detinated the motor REALLY bad. Broke two JE pistons and did damage to the other two. The worst piston damaged also damaged the cyl sleeve. Motor = totalled.

liam

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by liam821 &raquo;</TD></TR><TR><TD CLASS="quote"> Motor = totalled.</TD></TR></TABLE>

liam-0
blown motors- 23

lol

good write up, and i sent you a pm muckman


Modified by pissedoffsol at 3:43 PM 3/25/2004

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by pissedoffsol &raquo;</TD></TR><TR><TD CLASS="quote">
liam-0
blown motors- 23
</TD></TR></TABLE>

sad...but true...

 

beautiful write up

 

Nice write-up....

 

Good job on the write up Muckman.

Okay guys, Muckman and I have been talking about this, I am gonna offer the complete kit using straight male to male 10x1.0 to -3An adapter for the wastegate.

Intsead of the banjo, it'll be all male to male adapter.

I'm waiting for the 10x1.0 mm adapter to come in (2-3 days) and when those do, I'll snap some pictures for you guys.

Let's call this the Muckman Kit

Once again, good job Brian.....

Stan



Modified by Flamenco-T at 10:54 PM 4/7/2004

 

Very nice write up!!!!

Now write one up if your running a manual boost controller also.......PLEEEEEEEASE!

 

good job, i think im gonna get one

 

Bling Bling....

Solid job B...

 

Pissedoffsol had a question about the vacuum port on the turbo compressor. I don't think all turbos have this. Im pretty sure Precision turbos do. Its simply a 1/8" NPT port on the compressor housing. If you don't have one you can also run a -3AN line to your vacuum manifold if you have one. Popular vacuum manifolds from GE and Mcmaster use 1/8" NPT ports also. So you would just need to order a longer -3AN line from Stan.

Heres a pic of what mine looks like. I replaced the barbed fitting for one with a -3AN Male fitting.



Next step is how to incorporate this design with a boost solenoid.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Flamenco-T &raquo;</TD></TR><TR><TD CLASS="quote">

Let's call this the Muckman Kit


</TD></TR></TABLE>

Bad Form!

it should be the Muckfuck Kit

 

very nice write up man.... i think im going to get one..