Is this on stock NA8 BP05?

Yep, otherwise stock '97 BP with 550cc injectors, custom intercooler and a FM221.

Did Kevin at flimflam tune it? The curve could be so much better.

He did, I don't mean to flame him. I completely satisfied with his work. If there is anything wrong it's most likely my fault.

I looked at it today and it dosen't look like anything is impeding it's movement. Any suggestions on where to go from here if shaving it down would be unwise?

If the valve face will not seat flat on the turbine face, it's likely one or a combination of these:
- binding in the mechanism, valve, swing arm or actuator
- actuator adjustment keeping the valve from closing fully
- incorrect geometry in the assembly

The simplest thing to do is pickup a t3 eBay turbo internal wastegate assembly/housing as a replacement and reference. I've seen them on eBay for cheap and wouldn't be surprised if there are some members here with spares given the failures reported.

When I was inadvertently running too retarded timing in boost the EGTs cooked the flapper shaft and caused it to hang up and not close or open fully. And it wasn't consistent. Shaft ended up like a worm instead of a straight rod. May or may not be the problem but worth mentioning for the broader audience.

Nbcavolo could lay the WG housing on a sheet of plexi/glass and move the actuator arm to gain some insight on geometry too.

No plexiglass but setting it on my glass table showed me that the wastegate housing isn't actually flat. If I were to deck it I think it would bring the flapper even further from sitting flat. So I'm just going to buy another one and hopefully call it a day. Thanks for all the help guys it's much appreciated. I'm getting pretty close to finally slapping this th
ing on the car.

If you get a chance- shoot some pics and post up what you did here. That'd be a big help to anybody in the future that might run across something similar.

I'll be out of town for a wedding for a few days but when I get back I'll definitely try to get some useful pictures.

Figured I'd snap a picture of the actual problem before heading out.
When the flapper is sitting flat.
https://cimg3.ibsrv.net/gimg/www.mia...5c6c49b231.jpg
Spencer being a huge help
https://cimg8.ibsrv.net/gimg/www.mia...7531b50ed4.jpg
p.s using the in house uploader for pictures on mobile so I'm unsure of the picture size. Let me know if they're obnoxiously large or a problem.

Edit: Found a nick that was causing the housing not to sit flat as I mentioned earlier. That is not affecting the the housing in the picture.

Ikea table? :)

Haha yeah with the most uncomfortable chairs you could imagine.

On a turbo related note I picked up the new wastegate housing. It should be here next week so fingers crossed that I'll be on the right side of ebay roulette.

I picked up the "TC-T3DF" CHRA that Lars recommended for my particular churbo. Here are the measurements:

Compressor
42.57mm inducer
60.13mm exducer

Turbine
63.52mm inducer
46.34mm exducer

I'll try to get the old one out tomorrow to see how it stacks up.

https://cimg4.ibsrv.net/gimg/www.mia...223473df93.jpg
https://cimg3.ibsrv.net/gimg/www.mia...e18b82a727.jpg
Perfect match. We'll see if this resolves the bad noises. No obvious signs of failure except that the compressor side had an oil slick going on.

https://cimg3.ibsrv.net/gimg/www.mia...35f045a325.jpg
planning on porting the turbo on my MK kit, put a little smear of grease on the wastegate flapper, bolted it on and moved it so the flapper would make contact (had the lever held back with rubber band until I had it bolted together), this is what I see, is this going to be a problem? it looks quite a bit off, and on that one side it looks like it's not even sealing all the way

Check and see if the flapper slides in and out of the extension housing, mine did and had similar issues, could not build more then 10psi with it off centre

thank you for the reply. there is about 1-2mm of play, I did this test a couple times, the picture above is with me pulling the flapper such that it was as far towards the untouched side as possible, so this picture is the best it gets, other way it will be 1-2mm further up from the non-touched part. I can't believe it's so far off, seems like a major screw up on those who machined this thing

That should be too bad then this is what happened to mine Attachment 222269Attachment 222268Attachment 222267