I can't weld and need an alternative

[thehorak]

Hey All. This is my first time posting, but not my first time visiting these forums. I'm gonna be reconditioning my car's turbo sometime soon when I have a free weekend, and I might be changing out the internal wastegate door if it proves worn. This technically requires welding, though. If you look at the posted pictures, that ss tab with the two holes gets placed on and attached to the end of the ss shaft. This is done only after the new door and shaft is installed inside the turbo housing. For a better idea of this, there's a YouTube video of someone doing this same job and it shows what exactly I mean. This link takes you to the relevant scene.

Considering the turbo's heat and the fact that this door will be regularly opening and closing, is there a metal epoxy that I can use and trust to last for a long time? I can bring it somewhere for them to weld, but I need to bring the entire turbo, putting my car hard-down for the time being, and I need it to be ready on their schedule. It's tricky. I've never welded anything before, and I don't want to get into it. I've literally needed something welded twice in my life, including this time now. Lastly, I don't have space to keep the machine and all the gear.

So, is there something else I can do? The shaft doesn't have clearance below where the tab sits for me to add threading to that shaft. The gap between the hole and the shaft is really small, too. Any advice would be appreciated.

 

[Walkers]

Just buy new parts. No epoxy is going to hold up to wastegate heat

 

[thehorak]

Just buy new parts. No epoxy is going to hold up to wastegate heat

So you think welding would be my only option? These are new parts, btw. I don't have any plans to buy a turbo haha

 

[cvairwerks]

There are some alumina ceramic adhesives out there that will work to about 1700C, but you could buy a NIB turbo for the cost of a couple of ounces of them.

 

[MoonRise]

No consumer level adhesive will hold up to typical turbocharger heat levels, especially on the exhaust/wastegate side of the turbo.

Turbo and stainless steel usually means TIG welding. Hire it out to someone competent. Doable, but it has to be done 'right' to hold up (right filler material, right shield gas and possible back shield/purge, right material prep, right welding parameters, and a competent welder to do all that).

 

[thehorak]

Thanks everyone. My questions are answered. Gonna find me a welder.

 

[MOS3522]

Looks like the replacement part is the $300 range. Although you can find a "welder" who will do this repair for less than that, it will be very hard to find a good welder who will do it for less than that.

 

[welder4956]

Where are you located? Perhaps there's a GJ member nearby that could help.

 

[thehorak]

Where are you located? Perhaps there's a GJ member nearby that could help.

Outside of Bethlehem PA

 

[Walkers]

Outside of Bethlehem PA

Better question is What are you wanting to weld, and why?

 

[VR6ix]

The arm needs to be welded to the shaft after the wastegate is installed from inside the turbo. Even though the weld is outside of the turbo it's still going to get crispy hot, TIG welding is likely the only answer, but it should be fairly easy to weld and it's not going to see a lot of mechanical force.

Never heard of internal wastegates "wearing out" but it seems plausible

 

[mark-NJ]

So the rod part goes through the turbo housing and that link piece is welded on? Is that the totality of the project?

I'm 1 hour east in NJ, and if that's the total scope of the job, this is a 5 minute gig. I'm not a pro welder, but my SS TIG work doesn't **** by any means. If you're interested, send me a PM.

 

[thehorak]

The arm needs to be welded to the shaft after the wastegate is installed from inside the turbo. Even though the weld is outside of the turbo it's still going to get crispy hot, TIG welding is likely the only answer, but it should be fairly easy to weld and it's not going to see a lot of mechanical force.

Never heard of internal wastegates "wearing out" but it seems plausible

Benefits of the VR6 haha. On some of them, the bushing wears and digs into the shaft. They call it Wastegate Rattle. That pic is super helpful, thank you.

 

[Bigblue&Goldie]

Scribe alignment lines on the parts and take them to get welded.