Welding the tacked and grimed exhaust (with partial reused stainless pipes from the old exhaust) was a challenge indeed, and not too pretty. But I got it glued together eventually without it leaking. Good cleaning before welding helps a lot.
Well so I did a couple of runs, used it to daily to my job and done near 1000km on the engine now. There was nothing alarming when I removed the run-in oil, no metallic stuff. I did have some issues already, one leaking gas filter
(it touched some clamp and slowly grinded its way through, not linked to this new motor install though) and a faulty n75!
Yesterday I was logging to set up KFURL (load is following perfect but req boost is off) and I had throttle cut at 5000 rpm. I just drove it home in limp and found out that the turbo had its first big boy boost... I maxed out the 3 bar map, so well over 30psi
One of the gates had a small leak, a screw came loose on the diaphragm "hat" and was bouncing around inside, no damage though. But after fixing this (LOCTITE EVERYWHERE) and boost testing the system, the gates still wouldnt open! I found the N75 leaking into the TIP real bad, if I blocked it with my finger the gates would open right away. Time for a new n75... I put a straight connector between the lines for now, curious how boost responds now. Before it failed I would have around 1.1 bar boost at 4000rpm, creeping to 1.3. Airflow is 276g/s at 5800rpm, so she flows alright
I still have LPG injector left, its running a little rich up top. I am confident I can make it to 350hp without any problems with the current setup so perfect for low boost. I am running the k03 timing map still, with zero pull. I hope to feed in a bit more timing under load today with the emulator, if the boost control is functioning properly...
Here is a small video that I made when I finished the exhaust to show the valve sound difference!
https://www.youtube.com/watch?v=U0LA0w_Dkco