Modifying the BOV Flange Using a Die Grinder
6:15
37:24
62.5K views
At 6:15 in
Budget Turbo Yukon XL "Uncle Rob" Gets TiAL Wastegate & BOV Installed! (Single Turbo Kit Fab Tips)
What happens here
Using an air-powered die grinder with a carbide rasp bit, carefully carve down the inner edge of the aluminum BOV flange. The goal is to reshape the flange's radius to match the curvature of the turbo piping, ensuring a close fit for welding. Apply lubricant (like cutting oil or even WD-40) to the bit and flange to prevent aluminum from galling and prolong the bit's life.
Goal: Reshape the BOV flange to match the pipe's curvature.
Tools and materials
- Air-Powered Die Grinder — Reshaping the BOV flange
- BOV Flange — The component being reshaped
- Carbide Rasp Bit — Grinding aluminum
- Safety Glasses — Eye protection during grinding
- Lubricant — Preventing aluminum galling during grinding
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