How to die-grind alloy without trashing the engine?
 

Hi all, I am getting an alloy elbow welded onto the end of the turbo intake for better packaging, and of course I'll die grind the inside of the join. But I have read previously on here that when die grinding the intake plenum, tiny bits of heated alloy can embed themselves in the wall, and then later when the wall itself heats up, those bits are released to wreak havoc inside the engine. So I figure the same thing could happen to the turbo.

Then my question is, what "treatment" do I give the newly-welded and ground front turbo housing to dislodge any embedded alloy bits before I reinstall it? Hot-tanking, sonic discombobulation, what?
Thanks heaps :)

Extrude hone.

I've fabricated 2 intakes and repaired the first one 3 times and have never had a problem. I think you're blowing the issue out if proportion. Just my opinion though.

Perhaps using carbide cutters instead of aluminum oxide abrasives?

--Ian

Well, I do use carbide cutters exclusively since I'm too impatient for aluminum oxide.

Please produce the source of this claim.

First i've heard of these heated alloy deposits "dislodging" and going into the engine.

Also, steel > aluminum.

Well guess I am effed ~shrug~

Bullshit. Any piece of aluminum small enough to embed itself in the crevices left behind by a grinder is going to be either small enough to pass through the engine with no damage, or small enough to heat up and burn in the chamber, or both. I would not worry about it.

Awesome, thanks very much everyone, will die grind with a clear conscience. I did a search to recall where I read about it, and I had conflated die-grinding with sandblasting an intake plenum and not cleaning it properly. Thanks again.

Yup. A number of Miata engines were ruined in this way (aluminum oxide abrasives) due to the work of one particular machine shop about 15 years ago.

--Ian