The Tiny Turbo Porting
Okay, I figured hey, I could buy a 16g or 14b. But why? This is cheaper and I would throw it out anyway If I bought a bigger one. Or try to sell it for a few measly bucks. No, I headed for the port!
Besides the turbo has 58,000 miles on it and spins well. Here goes....
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The left is a pic of the stock size. The right is after I ported it. The left picture doesn't show the inside very well. I opened it up a few inches down using the 16g gasket as a template. Note: I ended up polishing all of the following better the next day. I snapped pics fast before my battery croaked. Plus, It was 10 PM and the neighbors do not like power tool sounds at night.
I used a Carbide bit with a high RPM drill. Then used a Dremel to smooth it down some. I suggest an Industrial strength Die Grinder. This took a long time without it. I covered all openings during porting with Duct Tape. The top of the turbo I stuck an oily rag way down it to catch bits of metal followed by constant vacuuming.
The Wastegate side of the Turbo
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The left is original. I ground a little and said "OOPS, I'll snap a quick photo." The right pic is the finished product. I ground the metal behind the flapper to let it open more (it opens very little stock). Then opened the hole up which the flapper covers (carefully not too much that it doesn't seal when closed). Finally, I ground the "blast zone" opposite the flapper side a little for more air to flow through (top right of the hole and some of the left top also). The pic doesn't show but there was a big lip there impeding the flow. I left the turbine blade area alone.
*A Must See Below!*
Pics of turbo together (kinda) click1 and click2 Note the NEW O2 SENSOR!!!!!!!
Thanks to Tom Stangl and http://www.vfaq.com/FAQlocator.html for sharing and providing all the great info!!!!