So, out for a drive again and really wishing I had the Turbosmart unit installed. So, I began to look at what I might do to try and adapt the unit to my K04.

I pulled out the digital calliper to take a look at some of the dimensions. Low and behold, I found the problem. the Turbosmart unit has been machined to 15.75mm from mounting face to mounting face. Looking at my OEM JCW K03, it is in fact 17mm as you mentioned. No matter how you slice it, there would be a 1.25mm gap between the unit and the inner mounting surface. So clearly Turbosmart either mucked up a batch of BOVs, or the incorrect part ended up in the box. I've written to them to find out what the issue is, and if I can get a replacement. More to follow.

 

Good sleuthing. Yeah that definitely doesn't sound right. For sure not EFR specs, plus bolt pattern is a little different.

Wonder if there's a triple k frame for a Ford or other that uses that spec. Vlad is cooling with the hood open at the moment. I'll pull mine out and measure so we can see what the normal spec is. With that I don't see how they do anything other than send you a new one.

 

I've got some 1/8" thick silicone gaskets (rated to 400f) that are the perfect inside and outside diameter. They would be enough to seal the 1.25mm gap without preventing the outer o-ring from sealing. Tempted to pop the unit back on with the silicone gasket and give it a go

 

I wouldn't. If it comes loose guess where it goes? Measured mine out at 16.73mm. Seal is a bit compressed from age. Black on the unit itself has faded almost to a brown lol.

 

OK, well that definitely answers that question. Yours is a full millimeter deeper into the turbo than mine. Really appreciate you taking the time to look. We’ll see what Turbosmart comes back with.

As an aside, I tried the silicone gasket. Completely solved the problem. Runs like a champ now

But yeah, agreed. Risk isn’t worth the reward should this bloody expensive turbo eats the gasket. I’ll take it out once the car has cooled down.

 

Put it all back together and took a few pics from inside. Had to scale up the 320 x 240 pics from the cheap non-articulating borescope I picked up years ago. The new ones that connect to your phone have better quality but you can see it seals. When I first removed it the o-ring on the end was missing and I about had a cow. Found it stuck to the face inside. I had just pulled it a couple of months ago to clean and lube so I was thinking it fell out when I re-installed it. It's all good though since I got my cardio exercise for the day

 

Measured mine for comparison and it measure just over 16mm (as the battery died I could only see looking at the tape) like Tigger2011.

I would say maybe the parts got redesigned along with the box, although the part numbers are still the same.