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No aluminun tube? You mean that you have a one piece rubber hose, from the turbo charger aliminum housing to the intercooler inlet? Strange indeed. The expected pipe runs horizontally down at the level of the bottom of the rad, over to the left side of the engine bay.
As you tighten up the wastegate, you should feel better spool up response, and see a higher pressure in the 1st two gears.
What you are describing from the casting rework is typical. It can be a bit hard to evaluate at first, because more power and smoother are some how contradictory.
I was wondering how your work went, and when you would post. I was busy too. I removed my casting, and cut it in two, between the thermistor mounting boss, and the first bend. I then ground the S**T out of it. I found that 1" sanding drums work better, and that 1.5" drums, when they can get into the casting will cause severe run away occilations. Definate safety hazard. I used medium and fine sanding drums. I removed a lot of metal, all of the way through. It was raining this AM, so I was not able to evaluate the change. I know that for this work, I am on the wrong side of the 80:20 rule, but I wanted to see what the yields would be.
So, how far up were you able to blend the transition?
Also, I measured the throttle bore ID, and did some calulations. The big end discharge lip needs to be 2mm thick. The stock casting discharge ID is as cast, and the castings are never perfectly centered, and all will be a bit different. I ground that to a uniform 2mm all around.
I finished the interior with #240 and then #400 grit wet/dry sandpaper, using lots of water.
So I really did get carried away. A good measure of which is how crazy your spouse thinks you are after doing that stuff for hours! Hands are very sore too.
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