With nothing else to do 'engine wise' I thought id go ahead and sort out the K04.
It had a few problems that needed to be sorted in order for it to fit and work.
First off, its the K04-023 from an Audi TT/S3 and has a hold in the exhaust housing for an exhaust gas temperature sensor [EGT] so I had to get this blocked up. I had thought about maybe even fitting an EGT sensor but figured it would be easier/cheaper to just block it up.
That was until after research I found the hole to require an M11 x 1mm pitch blanking bolt which were impossible to find.
So I bought an M12 x 1.25 brass blanking bolt/washer and an M12 x 1.25 top and bottom tap.
I thought the tap might completely eat the existing threads and leave a smooth hole, but it didn't and worked a treat. The brass blanking bolt tightened right in
Then the forge actuator came in the post:
Fitted it to the K04 and the housing was just not going to fit with the radiator in its way so had to sort this.
I thought about just switching the plate [that holds the actuator] the other way round, but it just wouldn't work because of the shape of the plate. So thought about using the standard actuators plate.
Its only after I realised I could have just ground the other side of the plate where the actuator is crimped round the centre hole. Butchering it seemed to work just as well:
This allowed me to bolt the actuator to the other side of the plate:
Then allowed me to rotate the turbo housing to a much better angle for it all to fit:
Simple enough fix, but well worth it. Would be a massive pain if I couldn't get the housing rotated down more.
Does anyone else think there's not a lot of thread left on the actuator rod for pre-load? Where it sits now, the waste gate is closed tight, but just. If I had a red 17.5 - 20psi spring fitted, how much more thread [if any] would I need to put approximately 23psi on it? Might have to space the actuator away from the mounting bracket a bit...