Turbo-Manifold bolts/studs Heaven

[KickAss]

I am starting this discussion to see the various solutions in the market today for flange bolts that seem to back out all the time, especially on the manifold-turbo joint in the Evo X's case. I was researching for some and found the following options so far. This thread is purely for informational purposes and technical discussion only. If people feel like asking questions about which one suits them better and where to buy them, please create a separate thread.


Option 1

Name: Inconel Studs with Locking Hardware
Brand: Trackspeed
Price: ~155 for set of 4 at the time of writing this
Likelyhood of backing out: None from online research, no experience reported on this thread.

Summary:

Don�t allow the failure of an inadequate $2 stud to ruin your next track day. Eliminate turbocharger fastener failure with Trackspeed Engineering�s Inconel stud kit.

Our stud kit includes:
- 4 40mm OAL M10x1.5 Inconel studs with rolled threads
- 4 M10x1.5 Stage 8 fastener kits
- Small bottle of Resbond 907TS

See below for a detailed description of this Trackspeed Engineering exclusive product.

________________________________________________________________________

For years, the fastest turbocharged Mazda Miatas in the country have struggled with the issue of fastener failure. The stresses and strains of extreme thermal cycling, high-RPM vibration and high g-force cornering combine to exceed the high-temperature yield strength of standard mild steel or normal 304/316 Stainless steel studs. As the yield strength of the fastener is exceeded, it begins to expand, or creep, causing an immediate reduction in preload on the nuts � akin to literally loosening them with a wrench. Once the fastener has worked its way loose, vibration will continue to spin the fastener off. If a high quality locking nut is used, the entire stud will spin out of the manifold. Safety-wiring all four nuts and studs together is only a temporary fix � after only a few sessions a steel stud will creep and cause exhaust leaks regardless.

A material-based problem requires a material-based solution. Enter Inconel, a nickel-based superalloy that sees duty in environments such as jet engines and nuclear reactors. Inconel is available in a wide variety of alloys, allowing Trackspeed to select an alloy that had a similar coefficient of thermal expansion to steel, but far higher high-temperature yield strength. Inconel studs do not exhibit the same creep when exposed to high-temperature stresses, allowing the fastener to maintain preload and work as intended.

Trackspeed Engineering�s Inconel studs are machined in the United States of America specifically for use in turbocharged Miatas. Because these are not off-the-shelf items, we are able to specify exact dimensions to ensure adequate thread engagement in the manifold as well as ease of installation with the manifold in the car. In addition, we were able to specify rolled threads which cause less stress concentration during production and result in a superior fastener. The end result is an exceptionally high-quality stud designed specifically for cast manifolds tapped to M10x1.50.

In order to complement our high-quality studs, we have chosen two products of similar quality. Stage 8 Fasteners provides the nuts, retainers, and clips for our kit. These nuts are significantly easier and faster to install than standard locking nuts or copper split-locking nuts. Once the nuts are all installed and tightened, retainers and clips are installed. If one of the nuts attempts to back its way off of the stud, the retainer interferes with its surroundings and prevents the nut from loosening any further. In order to fasten the stud into the manifold, Resbond 907TS thread locker is used. 907TS does not exhibit the temperature deactivation that other chemical thread lockers do, but is still mild enough to be removed with hand tools should the need ever arise. It is the ideal thread locker to complement our studs.

Trackspeed Engineering specializes in bringing high quality track-proven products to the Miata community, and we are proud to put our name behind this exceptional product. If you have any questions regarding this or any of our products, do not hesitate to contact us.

[KickAss]

Option 20

Name: Stage 8 Imports/Metric Locking Header Bolt Kits
Brand: Stage 8
Price: Unknown
Likelyhood of backing out: None from online research, no experience reported on this thread. Similar to Option 1, perhaps even sourced from the same manufacturer.

Summary:

Stage 8 Locking Header Bolts easy to use and they are real assurance against horsepower loss or gasket failure created by loose nuts or bolts. The unique patented and trademarked functional design is just three pieces: a bolt (4130 Alloy Steel), a locking retainer and a spring clip. The header bolt kits are application specific as either hex head with a 3/16 recessed allen head or 12 point, USA or metric. All Stage 8 Locking Header Bolt Kits are sold with all of the necessary hardware for your application.

[KickAss]

Option 31

Name: Lock Nuts
Brand: Multiple
Price: Unknown/cheap
Likelyhood of backing out: Some from online research, no experience reported on this thread.

Top Lock Nuts Grade C (Perhaps not up to the task in a high temp and high vibration environment.


Reversible Lock Nuts:


Flanged Top Lock Nuts Grade G


Spin Lock Nuts Stainless Steel


Nylon Lock Nuts (Definitely will not work for manifold)


More Information:
http://almabolt.com/pages/catalog/nuts/lock.htm

Option 32(a)

Name: Hex Crimplock Nuts
Brand: Multiple
Price: Unknown/cheap
Likelyhood of backing out: None from online research, no experience reported on this thread.


Summary:

Could not find much information on this product. Not sure if up to the task for a high temp high vibration environment like a turbo manifold.



http://www.treadstoneperformance.com...Crimplock+Nuts

Option 32(b)

Name: Hex Crimplock Nut and Stud Kit
Brand: Treadstone Performance
Price: Unknown/cheap
Likelyhood of backing out: None from online research, no experience reported on this thread.


Summary:

Same as previous option but with studs as well


More info:
http://www.treadstoneperformance.com...nd+Gasket+Kit+

[KickAss]

reserved 3

[CrazyIvan]

Wouldn't safety wire be just as effective?

[KickAss]

Thank you Ivan, That was going to be one of the options as well

[mac11wildcat]

tracks dont require this stuff? i know everything on a bike has to be safety wired for a track day. ive never tracked a car so. great idea, btw.

[DocBoz]

i just installed the nordlock washers on my setup will see how they do.

[zabes]

Originally Posted by mac11wildcat

tracks dont require this stuff? i know everything on a bike has to be safety wired for a track day. ive never tracked a car so. great idea, btw.

Not that I have encountered.

I will be using these:

Name: Full-Race T3 & T4 Turbo M10 Stud Hardware Kit
Brand: Full-Race
Price: $50
Likelyhood of backing out: Gunna Find out

Summary:


Tired of Turbos loosening on the manifold? Professional and amateur racing teams agree: Full-Race's M10 turbo hardware is the solution! Designed specifically for high performance turbocharged applications, this high quality A286 stud is heat treated, solution annealed and precipitation hardened. The nut is silver plated A4-70 grade, allowing it to be used without anti-seize (keeps long-term service removal possible!)
By using 1.5 (standard pitch) on the manifold side and 1.25 (fine pitch) on the turbo side, the standard pitch thread will stay put in the manifold while the fine pitch 1.25 inconel nut will be easy to remove without dislodging/unthreading the stud from the flange. This works perfectly with your existing Full-Race turbo manifolds (which typically use 3/8-16 hardware, the old industry standard) - all you need to do is run a 10mm x 1.5 tap through the old 3/8-16 threads to chase them and it works perfectly - Sierra Sierra Enterprises does this on their time attack Evo.

Application Notes:

• 4 studs/nuts included in each set.
• No washers, lock washers, safety wire or fastening plates necessary.
• M10 is for T3 and T4 turbos.
• T25 turbos require M8

[KickAss]

Good suggestion Zabes, be sure to report back your findings on here.