'90 W250--'89/91/92 Ramcharger

[Tacoclaw]

It welded to the flange, but a wafer wheel would have them separated in about 10 minutes. It's got 1.5" long beads of weld down it's length with 1" gaps between them. Then no weld at all on either end.
I'll just stick some keystock in there and weld it up.

Well, I won't, but someone who won't make it look like ass will.

[earthdad]

Is the aftercooler aluminum? If the housing is steel and the core is aluminum, those might not be welds but rather some type of adhesive or cold weld.

[Tacoclaw]

Nope, it all seems to be steel, pretty thick stuff as well. I'll try to grab a pic of the welds later on. They're extremely nice welds, almost robot-esque.

[PToombs]

I'm not sure what you are talking about. That looks normal to me. When you bolt that to the head, the flange should seal to the head. It doesn't matter if the cooler part is sealed to the outer housing, the pressure is still inside the housing. I think it's an installer error, you forgot the gasket or something.
Put a fat bead of silicone on the flange and put that sucker back on!

[Mark Nixon]

Put a fat bead of silicone on the flange and put that sucker back on!

To that I add:
USE THE GRAY RTV!

Mark.

[dazedandconfused]

I don't see anything out of the ordinary with it. You sure the mounting flange on both are flat?

[PToombs]

Put a fat bead of silicone on the flange and put that sucker back on!

To that I add:
USE THE GRAY RTV!

Mark.

No way! Ultra Copper all the way!

[Tacoclaw]

The air comes through the finned core in the center, and the sealing surface is the flange with the bolt holes all around it. Since the hole is between the core and the flange, there is a leak there.

I just said fkcu it and welded it up myself today. My welder bailed on me and to be honest I'm just getting tired on waiting on sthi to get done. It looks like what? but it works. I drilled out the WG port on the HX housing and it's 'gating off around 30psi. Between me drilling all the way through and the spacer I'm using not being divided it's doing a pretty good job at controlling boost. I'm not pushing it any farther since Hineman wrecked it with his 6x16's for a while and I've been driving it for 4 days with a horrendous boost leak. The compressor housing has more oil in it than my oil pan.

I haven't managed t get the EGTs over 1100 yet, though I've had it right to it on a good 3rd gear pull. 70mph stats are 8psi and 800*.

[AHineman]

Heck, you've had that turbo apart a dozen times since I sold it to you. It was on the rowdy ranger for a little while as well. I think you got your 40 something dollars worth.

[Tacoclaw]

It's funny I spent all that time porting out the housing for that S300, then when I had the chance to port the life out of the HX housing I drilled the 'gate out and threw it on the truck.

You and I both know I didn't get anything out of it's time on the Ranger. The trip you went on was the 2nd longest trip that truck took.

[AHineman]

Have you heard any more about your d tech?

Planning on putting the twins back on after all this crap?

[Tacoclaw]

Nah, I haven't asked lately. He'll get ahold of me when it's done, no use bothering him since it's running now anyways. I will put the twin stuff back on, but it won't be right after the S300 gets back. I'll just drive it like this until I get tired of all the rattles.

I've got to admit it runs pretty damn good with the H1c on it. Pulls hella hard down low but it runs out of breath so fast. I took the chickie for a ride in it and was trying to explain how it used to run. I floored it, then told her it pulls just like that, but all the way through the gear not just for a second.

[AHineman]

She ought to be used to things being over fast.

[Tacoclaw]

I have some sort of stamina joke in the turbo's favor in mind here, but I'm tired.

I'm going to go cry myself to sleep now.

[PToombs]

Levi, you're missing the point on the leak. (I'm not going to get into the being done fast comment ) It doesn't matter if all the air goes thru the cores, as long as it doesn't go out the flange, it goes into the engine. If it leaks between the core and the housing, it won't affect the boost pressure, but may raise EGT's a little. You said boost pressure was way down, so you have/had an external leak.
You dig?