So I'm using a ZPI log Manifold...... The part were the waste gate bolts on is getting warped... I can put a pretty darn big feeler gauge in between it on the car... So I got it all true'd up at a machine shop. but still...
The problem is happening again .. Its still warping.. and the shop cant grind anymore down due to the lack of threads left to bolt the waste gate on.

So I was thinking about cutting the flange off and welding a new one on.
(worst case)
Or

Buy a new ZPI mani that's in good condition, but i doubt i can find one... AND I'm pretty upset with the quality of the manifold.(ugly as hell) so i wish i could run something else even if i have to take it to a pro welder and get it customized to fit with a TDO5

Is there another manifold out there that i can use that will bolt to the tc head and to a TDO5 turbo without changing the set up of my inter cooler piping? Maybe with just some slight modification?

 

You can always do a through bolt design instead of threading in the flange. In other words, drill out the threads on the flange. Insert a stud or shouldered bolt through both the wastegate and flange and use a nut with lock washer on the other end.

Stopping the warping....that's another battle. Finding out WHY it's occurring would be more advantageous to you. Possible too high of EGTs for material used?

 

Thats what i did and its still blowing through heres some pics

 

U can see the brown stuff blowing out

 

could weld the bov to the mani lol

 

Wow my old kit o how i miss it lol but to what paul said get two studs welded to the mani and use bolts. But i meet a guy online that had new zpi mani if i need a new one

Sent from my MB855 using Tapatalk

 

I have studs in them... I need to belt sand the flange to make it flush but if i take anymore off the threads will go inside the manifold.

 

I had a similar problem with mine as well. I never did really find a permanent solution, like you said, you run out of metal after a while... but I do have my old manifold if you want to try and salvage the pair. Just swithed over to a TT mani for the ZPI assembly.

 

I really like what u did to make urs a TT mani. U use a TD05 right?

Do u have the link to how u made it? or can u tell me what materials id need and i can take it to my buddy whos an amazing tig welder and air/fluid design engineer( so after hes done he can put my mani on a flow bench and test the air flow and make it perfect for me)

 

Step 1) Find someone selling a TurboToyota (Mitzu flanged) aka replacement ZPI manifold
Step 2) Buy that ish! :D

I didn't make this manifold. I bought this from another member recently and upgraded my old ZPI log mani with this setup. *modifications required.

 

they sell a t3-->Mitsubishi flange adapter. with that u could rock any t3 mani with a 16g :D

 

quick fix some exhaust leak paste from auto zone.
i had a problem like this where the pressurized side of my waste gate was leaking from a small wrap. i used a bit of exhaust wrap in the shape of the gasket put exhaust leak paste on it and sandwiched it between two thin metal gaskets to create a sort of compressional seal works for me great.