Stud/fastener questions

Dweezle · Postby **Dweezle** » Thu Sep 29, 2011 11:46 am

I picked up a turbo kit, but have run into a few issues while trying to put it together on the lounge room floor.
Girlfriends at work

Kit is a TD04 Greddy/Mitsu turbo
ETD manifold
turbo tony downpipe

Issue 1 is the Turbo to Manifold.
The studs seem to be M10x1.5, they seem to fit into the manifold, but are too round for the turbo bottom plate.
That appears to be almost M9, M8 seem to have a bit of wiggle room.
Also the studs shoulders are too long.

Issue 2 is the turbo exhaust to downpipe.
The studs are the right diameter here, but the shoulders are so long that the nut at its tightest still has almost a centimetre gap between the downpipe and the turbo.

Issue 3 is i have a banjo connection on the oil feed line, but no banjo bolt.
Now i have found i require a M10X1.25 banjo bolt, but i am unsure of the diameter of the feed hole in the bolt to make sure the restriction is correct.
Would 1.5mm sound right?

Does anyone know someone in Sydney that i could take this to, that could help sort out the fasteners?
Any help much appreciated.

zossy1 · Postby **zossy1** » Thu Sep 29, 2011 12:00 pm

Issue 1 sounds like it could be solved by drilling the turbo flange to accept the M10 stud... But just check to ensure that there is enough space for an M10 nut to fit at each stud he on the turbo.

Issue 2 sounds like you need to pull out your tap and die kit and extend the threat of the studs to permit them to fit. Alternatively, a spacer or a number of washers under the nuts should work if I understand the problem.

Issue 3 sounds like you need to make a visit to Pirtek. I don't use banjo fittings personally, as gas thread fittings are just better IMHO.

I also think that a turbo can never have too much oil (as long as the drain can cope). 1.5mm sounds too small but that may just be me - my turbo runs 3mm ID lines for both oil and coolant and a 14mm (approx) oil return - all gas fittings.

Dweezle · Postby **Dweezle** » Thu Sep 29, 2011 12:37 pm

Thanks mate,
Just realised another issue, The turbo to mani studs are way too long anyway.
Dumb question number 347 from me, where do you buy studs? :oops:

From my measurements, i think i will need 40mm studs.
10mm Manifold
10mm Shoulder, the turbo to mani plate is close to 10mm thick.
say 20mm nut section

Then they should all fit nicely once i drill out the turbo to 10mm.

deviant · Postby **deviant** » Thu Sep 29, 2011 1:56 pm

I just put a new GT2560 on my car...

The manifold to turbo studs are M10 but the holes on the turbo are something like M8 which is what they are in the OEM (Nissan in this case) application. I had to drill out the holes on the turbo to 11 or 11.5mm and the same on the gasket. A bit nerve wracking drilling in to your brand new turbo but easy enough to do.

Your studs do not sound suitable at all, personally I would not take up the gap betwixt nut and mating surface with a stack of washers, get the right studs and nuts for the job.

I used http://www.sonicperformance.com.au/ to supply all my parts, the bloke on the phone really knew his stuff to.

If you want to make sure nothing will come undone in the future you need to buy:

http://www.034motorsport.com/fluids-che ... p-609.html

and: http://www.034motorsport.com/turbocharg ... -1329.html

and: http://www.034motorsport.com/turbocharg ... 18953.html

zossy1 · Postby **zossy1** » Thu Sep 29, 2011 2:00 pm

You need to find a local fastener supplier. Ours down here is called Bong Bong Engineering (I kid you not!). If you google "nuts and bolts" in your area, or check the yellow pages, you should find what you need.

Good luck!

BTW, please be careful when drilling that turbo flange - you do not want ANY shavings entering the turbo/wastegate ports or oil/water galleries.

trader · Postby **trader** » Thu Sep 29, 2011 7:15 pm

Gidday Dweezle
Have sent you two messages today which should solve your issues...let me know if you cant access them.

Dweezle · Postby **Dweezle** » Thu Sep 29, 2011 7:18 pm

I havent received any yet? Bloody PMS not working again maybe?
Maybe i have had to many coffees or something

trader · Postby **trader** » Thu Sep 29, 2011 7:35 pm

Hi Dweezle
Her's the jist of my messages - you can email me on bolts@netspeed.com.au with address

As I recall I never actually put everything together and certainly didnt notice that two of the holes in the manifold werent tapped properly.
Your assumption of where the bolts fit is right.
Now I come to think of it on the miata forum site someone did mention that the Tony turbo had a thinner plate the normal. The arguement went along the lines of did that matter (it didnt) and no mention was made of the need to increase the stud thread. I'm pretty sure they are m8x1.25 and the holes in the manifold would be m10X1.5.
If you would like to send me your address I will hunt up suitable tap and die for you.
cheers

I just read your request regarding studs etc. I went looking and found the oil feed line banjo bolt on the floor of my shed. It is still in the oil feed line package that I purchased for the TDO4. Note the TDO4 has a floating bearing (that's why there is play in the impellor from new.) and probably of smaller size than other turbos. The studs were bought from Flyin miata who knew what I wanted them for so am surprised they dont fit. I ordered 45mm so if they are longer than that will need to be cut down.
Let me know if you want taps etc and I will send them down with the banjo bolt when I get your address.
Kicking myself for not assembling it as you have done as I would have resolved issues before selling...

bear2230 · Postby **bear2230** » Fri Sep 30, 2011 12:07 am

Hey Dweezle.

If you can wait until next week you can bring your whole setup to my work and we can assemble the whole thing. I will probably have everything you need in the shop as well as all the machinery and taps needed to deepen threads, ect.

3 Production Ave Kogarah. Can't miss it, there is a great big FL on the building.

Richard.