DIY: Adjustable wastegate actuator

[sutyak]

After shortening my wastegate actuator rod too much and ending up overboosting I decided not to take shortcuts this time and make the rod adjustable.
I hit 11psi with 1/4" of preload.
This way I can properly preload the wastegate for the stock psi (9.5), or crank it up later if I wish without much hassle.
I can also lengthen the rod to keep it from boosting if I desire.

Note: this won't work for all applications.
The rod must be straight, and there must be ample space for the turnbuckle.
This is an IHI actuator from a 1987/88 Ford Thunderbird TC 2.3.

Parts:
- wastegate actuator
- 1/4" turnbuckle from Ace Hardware
- 1/4" nut to lock it in position.

Tools:
- Welder or 1/4" die
- Cutting tool
- Vise (to hold parts while welding)

I bought a 1/4" die thinking I would just thread the actuator rod.
Before opening the die (so I could return it) I tested the welder on a part of the turnbuckle eye end.
The weld penetrated beautifully so I went that route.
I used a heat level C (from A-D) on my MIG welder using flux core wire.

After the install I went for a drive and it worked perfectly.

PICS







You can see I ended up cutting more off for a wider range of adjustability: