Crossover exhaust leak

pelky350

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My up pipe cross over tube is leaking only in one side by y collector up pipe will not seal. Just spent much time removing entire turbo system to seal this re adjust everything to make it come together right but now thinking it's possibly out of round somehow. It's the crossover from my previous 088 ats turbo that supposed to fit my new factory turbo but just will not seal. Any ideas? Exhaust donut, aluminium foil to crush in there? When I rev the motor I can clearly see it only coming from that one side after all the work I've done readjusting it multiple times now it's got to be that pipe. It looks fairly okay when inspecting it but not the best it just doesn't want to line up at the right angle like it may need bent towards the motor almost but this leak is pretty small I was hoping for just a easy repair not wanting to spent the cash on a r and d crossover right now alrwDy need many more pArts. Truck drives boost is good but i would like to not have this exhaust leak anymore and I know I will get a few more pounds put of it with it sealed
 

pelky350

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This is what happened to my first attempt at exhaust donut but it wasn't the right size from what I couldn't tell also much too this this leak it's maybe 1/16 of inch and this donut was like 1/2 in this and I trimmed it down to help it fit but it didn't work as I planned

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Thewespaul

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Is the donut clean? I’ve had to wirewheel them to clean rust that is built up to make it seal better. If it’s clean I would just replace the donut itself, they are pretty universal. Just cut the crossover somewhere easy and weld it back up once the new donut is on
 

pelky350

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Okay updated too quick probably but I can feel no pre turbo exhaust leaks now used foil to make a crush gasket on it and it worked! However I still only see 14 psi. My 088 had more boost on the same fueling . 90cc pump stage 1s and 60-1 typ4 factory turbo kit. It's sounds amazing performs well but I feel like maybe should have more boost? Wastegate leaking now? It's unhooked currently, someone mentioned maybe bungee it to from if truck somewhere and make sure it's locked out for sure?
 

Thewespaul

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If it’s just unhooked the exhaust will still push it open, you need to physically prevent it from opening
 

pelky350

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The factory turbo never came with a donut as far as I know I bought that from the parts house to try to stop this leak but it's solved now. I kept getting mixed opinions about the wastegate opening on its own while unhook but I'm gonna try and hold it back with something and test, I don't want more max psi but also not wanting any loss down low I'd it's leaking
 

snicklas

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Did you take the hex studs out and replace with normal studs? I thought you were part of that conversation a few weeks ago, but it doesn't hurt to mention it............
 

pelky350

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Yes I did that when I still had the 088 turbo. Exhaust leaks fixed now though! No more exhaust leaking noises in cab finally! Made a foil gasket for it works well carefully made and placed so nothing should come loose or enter my exhaust stream even if it were to fail
 

03wr250f

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I can tell you with my crossover I ended up putting it in a vice and bending it wider by 1/2'' Center to center of the pipe in order to get it to better seal.
 

pelky350

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Well I'm hoping this fix works, tax times gonna be big this year and my trucks been hurting after this summer. But has gotten many new parts, soon I'll have an entire new truck! Almost gone through at least half my major repairs now and proper maintainance buying only better products, only wanting to do these jobs once I've learned my lesson too many times now I'm willing the spend the extra minute now lol
 
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