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DIY manual boost controller!!!! 
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N00b
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Joined: Wed Mar 04, 2009 3:13 pm
Posts: 19
Location: nor cal
Post DIY manual boost controller!!!!
yo what going on every one im new 2 this site n i noticed that there isn't a Tech Article on How to Make a MBC in the tech article section So i thought that i would share it with all of you.

Materials:

(1) 1/2" Brass TEE
(2) 1/2" Brass Fittings with 1/4" Hose Barbs.
(1) 1/2" Brass Plug fitting
(1) 1" medium duty Spring (test a few by squeezing them with your index finger and thumb, you want it to be resistant, but not too stiff)
(1) 3/8 Metal Ball
(1) 3/8-16 Allen Head bolt 1 1/2"
(1) 3/8-16 Nut

Image


Tools necessary:

Vice
3/32 drill bit
3/8 drill
5/16 Drill bit
Small Hammer
Center Punch
Sharpie Black Permanent Marker
3/8-16 Tap
Tap Handle

Procedure:

Take the Brass Tee and put the plug in the top or bottom. (doesn't matter)

Image

Take the Sharpie and mark the center of the plug.
Take the center punch and small hammer and indent the center of the plug.
Use the center punch and hammer to indent the middle of the flat side of the tee.
Use the 3/32 drill bit to drill a tiny hole on the flat side of the tee.
Now, take a grinder and grind the Plug flush with the body of the Tee.
Take the 5/16 drill bit and drill a hole straight through the plug using the vise to hold the TEE still.

Image

Now, Tap the hole you just drilled with the 3/8-16 Tap and handle.
Take one of the 1/2" fittings with 1/4" hose barbs and put it in the side of the tee.

Image

Now take the 3/8-16 nut and thread it on the bolt all the way up it to the top where the head is. Screw the bolt TIP into the hole you just drilled and tapped.

Image

Flip the Tee over and drop the spring into the Brass Tee from the bottom (or directly opposite the bolt you just screwed in)
Place the Check Ball on the end of the Spring, and put the other 1/2" fitting with 1/4" hose barb on top of the check ball.

Now slowly screw the 3/8 bolt down until you feel a small resistance from the spring and check ball.

Run the 3/8 nut down to the surface of the 1/2" Brass plug and secure with the appropriate wrench.

Now, the barb opposite of the bolt, is fed by either the compressor housing OR the intake manifold. The barb that sticks out from the middle, now feeds the wastegate actuator.


To adjust boost pressure all you have to do IS:

Loosen lock nut, and turn bolt IN for more boost, turn OUT for less, tighten lock nut.

All parts are usually available at a Ace Hardware. Grab a sales rep and bring the required materials list with you. I know some hardware stores do not stock this stuff and will play 20 questions wanting to know WHY your needing this stuff so bad, just inform them that you are saving yourself $45 - $9.00 (worth of parts) = $36 dollars and some time by doing this yourself. You may have to check around, but parts stores DO stock this stuff, you just have to know EXACTLY what your looking for.

Good luck and hope I saved alot of you some $$$.

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Wed Mar 04, 2009 4:51 pm
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Joined: Tue May 22, 2007 7:10 pm
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Post Re: DIY manual boost controller!!!!
very nice writeup, thanks for posting.

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Wed Mar 04, 2009 10:00 pm
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N00b
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Joined: Wed Mar 04, 2009 3:13 pm
Posts: 19
Location: nor cal
Post Re: DIY manual boost controller!!!!
i cant give myself all the credit i had some help with it i just modified it lol

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Wed Mar 04, 2009 10:04 pm
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Squish Face
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Joined: Tue May 22, 2007 7:08 pm
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Post Re: DIY manual boost controller!!!!
Great post, made it a sticky.

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Wed Mar 04, 2009 11:29 pm
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Joined: Sun Jun 17, 2007 6:34 pm
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Location: La Puente
Post Re: DIY manual boost controller!!!!
You also need a small vent hole drilled in the brass tee.

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Mike
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Wed Mar 04, 2009 11:39 pm
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Joined: Wed Mar 04, 2009 3:13 pm
Posts: 19
Location: nor cal
Post Re: DIY manual boost controller!!!!
thats right im sure it said 2 drill 1 with a 3/32 drill bit but if not may bad but ya hes right :) good looking out mang

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Wed Mar 04, 2009 11:42 pm
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Joined: Sun Jun 17, 2007 6:34 pm
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Post Re: DIY manual boost controller!!!!
Yea you did say to drill the hole in the side of the tee. I just skimmed the directions. I just didn't see no pics of the hole drilled on the side. It would be a good idea to have a pic just so people can understand what you are talking about.

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Mike
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Wed Mar 04, 2009 11:48 pm
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Squish Face
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Joined: Tue May 22, 2007 7:08 pm
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Location: LBC
Post Re: DIY manual boost controller!!!!
1fast2G wrote:
Yea you did say to drill the hole in the side of the tee. I just skimmed the directions. I just didn't see no pics of the hole drilled on the side. It would be a good idea to have a pic just so people can understand what you are talking about.


BoostFrenzy wrote:
And you can use a 1/16th bit that's all that is required. And also, it's not "one of them" it's the side that goes to the wastegate or else you are just causing a boost leak...

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SOADweskey wrote:
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Illeagle wrote:
Broke trans sunday, rebuild monday, install tuesday. W00t.


Wed Mar 04, 2009 11:58 pm
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Talon of Doom
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Joined: Wed May 23, 2007 10:07 am
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Location: Long Beach
Post Re: DIY manual boost controller!!!!
or just put a plastic coupler between the controller and actuator and put a hole in that

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Fri Mar 06, 2009 7:52 pm
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