Safari Turbo Destruction/Rebuild

subzali

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Well, pretty bummed.

it started with the turbo seizing.

took it apart tonight and found cracks. The turbine housing is cracked.
2ABB4277-ED44-43A5-9CD1-726898DD7440.jpeg
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subzali

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The manifold is also cracked:
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rover67

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Dang. Trying to think about if we can weld it up. (The manifold). Turbine housing certainly can be replaced?
 

subzali

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Now the turbo can spin a little, but it binds on every revolution. But it’s a moot point because the housing is toast, so I think that means new turbo time. As I understand it this turbo was specially made for this application, though I know different replacement turbos have been used because it’s just a T3/T4 flange. Hopefully the guys at central motive power (assuming they are the ones to go to) can help take the specs of this turbo and find a replacement.

For the manifold, I understand that Turbo-Glide out of Australia were the makers of the manifold for the Safari system. I have reached out to them to see if they would be willing to sell me just the manifold. A guy on mud did this a few years ago:

If they aren’t willing or can’t, then I guess I might have to see if I can find someone to weld it, though it’s cracked on the inside so don’t know if welding will really be enough. I don’t know of any other manifold that will line the turbo up in the proper place for the rest of the Safari system to work.

Any ideas of root cause? The system did glow orange last summer because the cat got plugged in steamboat, but I generally don’t abuse it. The PO did romp on it though from what I understand.
 

subzali

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Putting this here, I talked to the guys at Turbo-Glide and they recommended muggy weld as an option:
 

subzali

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Progress
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subzali

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ATP Turbo has been very helpful so far. 👍
We may be able to figure out a turbine housing-only solution

Diesel Forward has not. 👎
 

nakman

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Ok so the hole is to stop the crack, then the groove you'll fill in with weldness? I bet Marco could weld the inside of that, he's got really tiny fingers. :weld:
 

J1000

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I'd recommend seeing if you could find a more modern turbo like a Borg Warner EFR or something that has similar specs to the original. Turbo tech has improved tons in the last decade so why not upgrade?
 

rover67

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Only reason to not upgrade might be that the turbos and systems seemed to be tuned around not building boost too soon so the engine is running open loop when it sees boost. That's what these designs depend on for enrichment from what I understand.

excellent work on the crack repair so far! it will turn out well!
 

subzali

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Well this isn’t good
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subzali

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Sent the turbo to ATP Turbo in California, hoping they can match it up with something that will perform similar and bolt in. Not sounding too promising though. We will see, they will get it tomorrow (Friday).

Welder is saying the cast manifold is really porous, so is not welding well. Oy.

And then there is fun (?) with bore scopes:
Cyl 1
IMG_2071.JPG


Cyl 2
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Cyl 3
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Cyl 4
IMG_2076.JPG


Cyl 5
IMG_2077.JPG


Cyl 6
IMG_2079.JPG


What can I tell from this? I don't know. I am worried about Cyl 1. But it's at TDC and appears wet with unburned fuel so can't get a good view of what's going on. I don't know if @powderpig looks at the forums these days and could provide any input?
 
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subzali

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And then there's the exhaust valves:
Cyl 1
IMG_2089.JPG

IMG_2092.JPG


Cyl 2
IMG_2086.JPG

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Cyl 3
IMG_2083.JPG

IMG_2085.JPG
 

subzali

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Cyl 4
IMG_2080.JPG

IMG_2082.JPG


Cyl 5
IMG_2094.JPG

IMG_2095.JPG


Cyl 6
IMG_2097.JPG

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The main thing I was looking for here were signs of cracks in the head or valves/valve seats due to the excessive heat that is presumed to have cracked the manifold and turbine housing. I am hoping those black streaks on the valves are not indications of cracks. I am not inclined to pull the head unless someone sees something that is an impending catastrophe.
 

AimCOTaco

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Sorry to see the carnage in here so far, but glad you're getting to the bottom of it by digging deeper.
Can I ask what you're using for a bore cam? Pics are pretty nice at least ;)

Not sure but the valves looked streaked more than cracked to me so maybe minor leakage or leaked a bit only when frying hot..
 

subzali

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Spark Plugs look ok
IMG_2023.JPG
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subzali

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I bought this borescope off Amazon, since it had the right-angle attachment. But the right-angle mirror attachment isn't really helping me at all. Straight ahead it seems ok though.
 
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subzali

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An update on grinding/welding the manifold:
IMG_2008.JPG
 

60wag

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Some of the valve stem seals are looking a bit leaky. Do you know if the head has ever had a valve job done? Are those plugs colder than the stock ones? Wits End runs a colder than stock variety.
 

subzali

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Yes, it had a valve job done about 80,000 miles ago. Running colder plugs than stock, these in particular are the MR2 Turbo plugs that I think Wits' End is also using for his turbo and I think are the plugs typically used for the TRD superchargers. Denso PK20R8

Safari recommends NGK BCPR7ES-11, which I understand are a Saab turbo application.
 
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