See how bad each surface is, how close to true flat plane. You might be able to use a different gasket material, or if too far deflected you might need to have surfaced.
Maybe your gasket is just degraded and cracked.
Did you use a new stock gasket when installing that custom upper box? You can't get to all the bolts to remove the upper in the vehicle?
Wayne H.
'91 Dodge Spirit ES 2.5L turbo 5spd
'05 PT GT 2.4T HO autostick (RIP)
'89 Plymouth Acclaim 2.5L turbo auto, "Slugmobile" yes, THE Slugmobile!
'89 Dodge Caravan SE 2.5L turbo auto, "Mean Mini" yes, Gus' Mean Mini! (Current best 11.699 @ 114.43 mph! - Oct 15th, 2022 Cecil County Dragway, MD)
MeanMini dragracing videos: https://www.youtube.com/playlist?lis...URZLB1RxGYF6vw
and other cars, trucks and motorcycles
https://www.youtube.com/user/SlugmobileMeanMini
I'm not the one who installed the intake....so I'm not sure the condition of the gasket. I can get a ratchet on 3 of the bolts, but the others are either too shallow or in the way of the intake bottom half. One of them is completely blocked by the wastegate can. I might possibly be able to get a hex key on the bolts (they're hex) because the short bent end isn't too tall. I can possibly even remove the wastegate can and move it enough to get the last bolt. Maybe I can double the gasket?
I think you are on the right track.
Removing the wastegate actuator is easier than having to deal with removing the entire head.
Be patient and remove the actuator and see if you can get to the remaining bolts. I can't remember but i think there are 7.
If the leak is from a slightly warped piece, then i think you could try doubling the stock gasket. They are already pretty thin, so it would only solve minor deflection.
Sometimes buying a new tool, like a short arm ratchet or a special short hex key socket helps in tight spots. You should be able to remove with 1/4 drive stuff, so that might help the limited access. Or flex joints and extensions to get where you have room.
Now that you know the problem, you are halfway there.
Wayne H.
'91 Dodge Spirit ES 2.5L turbo 5spd
'05 PT GT 2.4T HO autostick (RIP)
'89 Plymouth Acclaim 2.5L turbo auto, "Slugmobile" yes, THE Slugmobile!
'89 Dodge Caravan SE 2.5L turbo auto, "Mean Mini" yes, Gus' Mean Mini! (Current best 11.699 @ 114.43 mph! - Oct 15th, 2022 Cecil County Dragway, MD)
MeanMini dragracing videos: https://www.youtube.com/playlist?lis...URZLB1RxGYF6vw
and other cars, trucks and motorcycles
https://www.youtube.com/user/SlugmobileMeanMini
spray the new gasket with headgasket copper spray to give it some extra sealing ability?
or some kind of high temp glue....
either way, dont pull the head for that. there has to be a way to get the 2 halves off and get a straightedge on both sides even if you have to buy a second allen key set and cut parts of them off to make the tools to get the fasteners out.... easier than pulling the head.
i cut up cheap wrenches to make tools to remove the turbo with the engine in the car and the head on. sure i had to disconnect the mounts and rotate and move the engine forwards but it was worth it.
if you get them apart, buy the miller valve spring compressor tool so you can remove all the rocker arms. (a lifesaver)
http://www.ebay.com/itm/KD-3087-Vavl...914155&vxp=mtr
then you could file the lower flange flat if need be and use a shop vac to vac out any potential shavings with all the valves closed.
the upper doesnt have this problem of course.
brian
Originally Posted by turbovanman
So..unfortunately I didn't heed the danger to the manifold....my floorboard ejected itself in spectacular fashion and decapitated some poor ricer....I managed to blow the welds on the intake. Fortunately, me and the mad scientist didn't have to rip apart the block to replace the piston rings I fried.
Yikes. But look at how great it is to know what's wrong. The lower part should be fine then.
Wayne H.
'91 Dodge Spirit ES 2.5L turbo 5spd
'05 PT GT 2.4T HO autostick (RIP)
'89 Plymouth Acclaim 2.5L turbo auto, "Slugmobile" yes, THE Slugmobile!
'89 Dodge Caravan SE 2.5L turbo auto, "Mean Mini" yes, Gus' Mean Mini! (Current best 11.699 @ 114.43 mph! - Oct 15th, 2022 Cecil County Dragway, MD)
MeanMini dragracing videos: https://www.youtube.com/playlist?lis...URZLB1RxGYF6vw
and other cars, trucks and motorcycles
https://www.youtube.com/user/SlugmobileMeanMini
Done that with just boost after about 4 years of driving.
I've also done much worse than that with a N2O backfire.
It's going to be very difficult to clean out that crack well enough to get a non contaminated weld to repair it, so take your time to do it right.
Yeah....a guy I know(https://www.fathousefab.com/) with a decent rep for being a great welder is going to go over all the welds and gusset the plenum....hopefully it works well.
Well this is why pressure vessels are rounded surface. Cylinders, belled ends, ball, etc.
It doesnt take much to flex flat sides and 90 deg angles.
Pressure is always tring to make a box into a sphere.
Wayne H.
'91 Dodge Spirit ES 2.5L turbo 5spd
'05 PT GT 2.4T HO autostick (RIP)
'89 Plymouth Acclaim 2.5L turbo auto, "Slugmobile" yes, THE Slugmobile!
'89 Dodge Caravan SE 2.5L turbo auto, "Mean Mini" yes, Gus' Mean Mini! (Current best 11.699 @ 114.43 mph! - Oct 15th, 2022 Cecil County Dragway, MD)
MeanMini dragracing videos: https://www.youtube.com/playlist?lis...URZLB1RxGYF6vw
and other cars, trucks and motorcycles
https://www.youtube.com/user/SlugmobileMeanMini
Heat cycles, thickness and initial quality have a big role too. but ANY home made intake manifold must be better than a stock 1 piece.
Hah, i saw that pic on instagram but didnt put two and two together that it was your car. derp. At least it's diagnosed!
Dont push the red button.You hear me?
Let's hope that does the trick for you! Can't wait to hear a successful story.
Wayne H.
'91 Dodge Spirit ES 2.5L turbo 5spd
'05 PT GT 2.4T HO autostick (RIP)
'89 Plymouth Acclaim 2.5L turbo auto, "Slugmobile" yes, THE Slugmobile!
'89 Dodge Caravan SE 2.5L turbo auto, "Mean Mini" yes, Gus' Mean Mini! (Current best 11.699 @ 114.43 mph! - Oct 15th, 2022 Cecil County Dragway, MD)
MeanMini dragracing videos: https://www.youtube.com/playlist?lis...URZLB1RxGYF6vw
and other cars, trucks and motorcycles
https://www.youtube.com/user/SlugmobileMeanMini