AVO turbo kit for BRZ - initial build thread

[onzippy]

Yikes.. That's pretty obvious.

Keep us posted on how it works out.

[protpibe]

Yeah, it's not exactly minor lol.

My guess on the header warpage issue after experiencing it is that the header needs to be installed correctly the first time. Proper gaskets, proper torque pattern, and re-torquing as it's heat cycled. It seems like it's warping if it weight distribution isn't near perfect the first time it's installed, and once it's warped it's warped. Just my own personal opinion, I'm not sure how much validity there is to it.

[onzippy]

Originally Posted by protpibe

Yeah, it's not exactly minor lol.

My guess on the header warpage issue after experiencing it is that the header needs to be installed correctly the first time. Proper gaskets, proper torque pattern, and re-torquing as it's heat cycled. It seems like it's warping if it weight distribution isn't near perfect the first time it's installed, and once it's warped it's warped. Just my own personal opinion, I'm not sure how much validity there is to it.

Well.... I can be quite ham-fisted with tools sometimes. Couldn't find my torque wrench so they were tight getting off, I made them tight when I put them on. But I did go back a few days later to check and had to tighten them once more because the were loose. "Tight" being the measurement of what I remembered when taking them off several days prior. So far so good.

I have found my torque wrench since then.


So you throw a spacer in with the new gasket and let it warp back. In couple weeks take the spacer out... I'm half serious. Probably something I would try if I was doing the labor on my own car and all the other option required the outlay of more cash. Metallurgy is a little weird so...

[protpibe]

Originally Posted by onzippy

Well.... I can be quite ham-fisted with tools sometimes. Couldn't find my torque wrench so they were tight getting off, I made them tight when I put them on. But I did go back a few days later to check and had to tighten them once more because the were loose. "Tight" being the measurement of what I remembered when taking them off several days prior. So far so good.

I have found my torque wrench since then.


So you throw a spacer in with the new gasket and let it warp back. In couple weeks take the spacer out... I'm half serious. Probably something I would try if I was doing the labor on my own car and all the other option required the outlay of more cash. Metallurgy is a little weird so...

That's something I would probably try if I bought the kit used. Having bought new and plan on keeping it for a long time, I don't think I should resort to warping a part back into place lol.

Admittedly, it does sound like it might work though

[onzippy]

If i missed it, I'm sorry, but I wonder how much value added there is to bolting the manifold to a third mount point that must align in a perfect plane with two other surfaces. Sure there's some additional torsional stress with the weight of the turbo but I've had motorcycle exhaust bust a mount on the can and the whole damn thing is hanging from the header. That's about 4ft of stuff hanging in the wind from the manifold bolts for unknown period of time.

R&D knows best so if there's a risk, kudos to AVO for putting it in the design.

[aaguirre123]

Originally Posted by protpibe

Yeah I'm thinking avo gaskets may be part of the fix, but also if the header is already warped, I'm thinking I will need a new header. Not sure what effect the AVO header studs would have, but they now offer those on their website too.

The leak is pretty clear once you stick your head under the car





That was about 3 weeks ago I think, about a week after I had the OEM gaskets installed. I'm sure it's much worse now.

edit: Oh, and I have about 4,000km on the kit now.

i really like the AVO kit. the design makes the most sense. but when i see something like this... very disappointing. would you still recomend this kit? i was so looking forward to buying this kit.

[protpibe]

Originally Posted by aaguirre123

i really like the AVO kit. the design makes the most sense. but when i see something like this... very disappointing. would you still recomend this kit? i was so looking forward to buying this kit.

If the issue gets resolved by AVO in a timely manner, then yes, I would still recommend it.

I like the design and layout of the kit, I just don't want little issues cropping up. Everything else about the kit seems solid so I figure once this is resolved, it should be worry free from here on in. I did use Grimmspeed gaskets on the initial install and did not shim the bracket, so that may have caused it to slightly warp in on itself. The install was done prior to AVO modifying their kit and including their own gaskets so my expectation is that I'll be shipped a new header.

[aaguirre123]

Originally Posted by protpibe

If the issue gets resolved by AVO in a timely manner, then yes, I would still recommend it.

I like the design and layout of the kit, I just don't want little issues cropping up. Everything else about the kit seems solid so I figure once this is resolved, it should be worry free from here on in. I did use Grimmspeed gaskets on the initial install and did not shim the bracket, so that may have caused it to slightly warp in on itself. The install was done prior to AVO modifying their kit and including their own gaskets so my expectation is that I'll be shipped a new header.

i hope it gets resolved or else i'll be hesitant to buy their kit. by the way did you buy it directly from paul?

[protpibe]

Originally Posted by aaguirre123

i hope it gets resolved or else i'll be hesitant to buy their kit. by the way did you buy it directly from paul?

No, but I spoke with him a lot about it before I actually did buy it. He's a good guy and very knowledgeable.

I ended up going through a local shop just to make everything easier. I'm in Canada so they took care of all the customs, brokerage, etc.

[Pitman]

Originally Posted by aaguirre123

i really like the AVO kit. the design makes the most sense. but when i see something like this... very disappointing. would you still recomend this kit? i was so looking forward to buying this kit.

My AVO kit was fitted last August, and I have done about 10,000 miles with it, and no blowing issues. I believe that AVO are working on a thicker flange to eliminate the problem. With their level of customer support, I am sure any faulty manifold would be replaced. I would not hesitate is buying the kit all over again, if I had to make the choice.

[SkAsphalt]

Originally Posted by Pitman

My AVO kit was fitted last August, and I have done about 10,000 miles with it, and no blowing issues. I believe that AVO are working on a thicker flange to eliminate the problem. With their level of customer support, I am sure any faulty manifold would be replaced. I would not hesitate is buying the kit all over again, if I had to make the choice.

AVO has been great for my customer service so far.

[kbogarto]

Originally Posted by protpibe

So add me to the list of leaking header gaskets. It was initially installed with Grimmspeed gaskets but done before the support bracket shimming post was made. Everything was torqued and re-torqued after heat cycling a few times. I'm thinking maybe the header warped in that time without the spacer on the bracket? I've recently switched to OEM gaskets but the leak came back, I'm guessing due to warpage from the initial install. I'm currently awaiting word from Paul on the fix, but I'm thinking I may just get the header flanges planed to see if that will fix it. The small noise it makes honestly drives me nuts. Maybe I have OCD or something but I can't drive with my windows open with it leaking even a little bit

I'll post up results on how I get it fixed

Did you get your header fixed? Curious on any word from AVO about this. Thanks

[protpibe]

Originally Posted by kbogarto

Did you get your header fixed? Curious on any word from AVO about this. Thanks

Yup Paul looked after me.

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[Astroboy]

I want to hear from former 86 owners w/ avo kit on where they sliced their t valve for their boost gauge and where's the best line to connect it to.. please

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