Need help with turbocharger gasket on '84 4d55

[mazda diesel]

I need help as my gasket between my exhaust manifold and turbocharger keeps blowing out... it has the stock turbo and all, just I am running a bit over stock boost at 12 psi max any help would be appreciated
Thanks in advance
Seth

[pennyman1]

Have you checked the flanges on the turbo and the manifold for flatness? If they are good, then get the copper turbo flange gaskets - they seal better.

[mazda diesel]

Yes both are flat, I machined both of the surfaces for that. Where would I get the copper ones? I blew two steel ones and one fiber one...

[pennyman1]

I have seen them on ebay, but they should be available other places

[pennyman1]

Try this link:http://www.ebay.com/itm/Cometic-Copper-Turbo-Inlet-Exhaust-Gasket-TD04-TD05-Talon-Eclipse-Laser-63-5mm-/400346484453?pt=Motors_Car_Truck_Parts_Accessories&hash=item5d36828ee5&vxp=mtr

[mazda diesel]

Try this link:http://www.ebay.com/itm/Cometic-Copper-Turbo-Inlet-Exhaust-Gasket-TD04-TD05-Talon-Eclipse-Laser-63-5mm-/400346484453?pt=Motors_Car_Truck_Parts_Accessories&hash=item5d36828ee5&vxp=mtr

Hmm that isn't the right gasket, mine is triangle with 3 holes and that one is rectangle with 4 holes...

[pennyman1]

put in copper turbo gasket on ebay and they come up as a triangle too.

[mazda diesel]

hmm still didn't find the right one, maybe it's time to start my CAD program and get one made...

[pennyman1]

that could work - although you could probably make one yourself with a sheet of copper and gasket punches, then use an adjustable cutter for the big hole.

[mazda diesel]

Yeah I rekon that'd work too thanks Pennyman =)

[recian]

I'd be curious why tho. I've been doing research on my truck to do the 4d55 build but havent heard of guys running into this issue when over boosted. Most are running intercoolers and larger exhaust also. They say EGT is your enemy on that engine and if it's running high EGTs that could cause the gasket to fail prematurely. Main reason for the intercooler and better flow exhaust is to drop those temps.

[mazda diesel]

Recian, I'm not sure what the egt's run on mine, I haven't spent the $ to get a pyrometer yet, and I have 2.5" straight pipes. I am planning to do water/methanol injection on it so it'll be cooler

[recian]

That another option I've read about but intercooler is a safer way to cool EGTs and will help with performance alot. Not to mention it's a solid mechanical mod. Don't forget youre taking air beyond the pressures it was designed to handle that's the same temp as the gas coming out of the exhaust. You're taking heat with added pressure. That doesnt do much justice keeping the engine cooler. If the gaskets are designed to handle say 50-100 degrees over what a stock engine would put out then it will definately blow them out. (knowing most aftermarkets that sounds right) but a Cometic will definately work good if you can find one. 3" triangle is a common exhaust setup. Cometic makes great gaskets. Water/meth is good add but the injection system will have to be refilled eventually. Intercooler when installed is done and you can pick em up cheap on ebay or even used from tuner guys for a decent price. Having cooler air going into the engine will make a world of difference since youre trying to run higher boost. If I'm not mistaken I read peak boost on these was 13lbs.
Think of it as building your typical engine. Putting a bigger exhaust then trying to add NOS or internal mods wont do you any good because the intake is still a restriction, especially being a stock (and 1980s) turbo setup.

[mazda diesel]

Thanks for your advice, I don't know if a inter-cooler will work on my truck though as it isn't the mighty max body, it is a '87 Mazda b2600 as the body from the mm was almost gone from rust... and there's not much room in the engine compartment. I just made a gasket out of copper sheet and put it in the other day, as well as setting up a Franz oil filter in the truck (the ones that use toilet paper for the filter) I have most of the setup for the water meth injection, just need to get a pump and injector nozzle and run the wires and hoses

[recian]

Thats true. If i thought id end up with a 4d55 i woulda bought a mazda pickup. Ive always liked their interior and cluster styling in the 80s/90s