Hi all,

I haven't posted in a while, but now is the time.

I'm hoping that what I write makes sense, as I have googled the life out of this and am still no closer to understanding an answer!

I have a 2006 WRX 2.5ltr it is running a TD04.

I have been given a TD05H 16G which I would like to fit, however I have two issues, the first being my car is a front entry and this TD05H is a top entry.
I know from research that converting from one to the other isn't too difficult. Is there anyone on here that can do this?
Secondly and my biggest issue, the exhaust or turbine housing flange is damaged. This is the 3 bolt flange. Two of the bolt holes have snapped off the flange leaving just half of the hole, I do not know how this happened apart from them possibly being too tight and its snapped the cast.
I have read that you can weld or braze repair cast iron. unfortunately I have not found anyone who can do this.
Weirdly enough, there is a stainless steel flange aswell, but Im not sure you can weld CI to SS.
I have some ideas in mind but was wanting you guys input.
1) repair the flange using mild steel and having this welded to the damaged holes.
2) Have the flange from my TD04 cut and welded/brazed to the TD05H
3) Cut the 2x damaged holes from the TD05H, drill some holes in the CI flange and also the SS flange and bolt them together to create an adapter of sorts, using 2 gaskets one on the CI side and one on the SS side to the engine. I have looked on Ebay and seen some mild steel flanges would it be better to use one of these?

I dont really want to start creating a Frankenstein turbo and mixing parts from other turbos.

The TD05H I have is complete with all the piping etc it is just a case of converting it and then resolving the issue with the 3 bolt flange.

Any help would be appreciated.

Cheers

Steve

 

I'd find one without a damaged flange.

 

Try Craig bellworthy.
He had some converted tdo5's for sale recently.
Not sure if he still uses the forums,he is on fb

 

Or get your td04 rebuilt with bigger 16g wheel.
comes back like new with a warranty.
Much better than messing around with an old td05 with broken bits and converting to do.
I used turbo dynamics.

 

The bolt holes prob broke when they were undoing the bolts to remove it.

The turbo i bought had one corner break off leaving just over half a hole. I got a piece of steel, about 5mm thick, created a big ol washer, made sure it covered a fair area on the turbo and that the locking nut fit with thread to spare. Did it up real tight and have no problems.

Im not sure how i would feel if it was 2 bolt holes broken though.

If you can afford it buy a refurbed one, if not then look for a TD05 housing on ebay and gumtree or put ads out. Should be an easy swap from what ive heard, not done it myself.

 

I have a TD05 I might sell front entry £180 delivered.