On to yesterday. As mentioned above, haven't been boosting the car really as I know it'll kill the gasket if I do.
Upside: 37mpg average over 140 miles I've done this week.
Downside: Some of the most boring 140 miles of my life.
Drove to Ben's yesterday and ended up taking some stuff to the tip in my car.. We decided that the M10 job could be put off no longer and the snapped bolt was the perfect excuse. On the way back to his, noticed the car wouldn't make more then about 7-8psi.. Investigations found this was loose:
Luckily for me, I got to take the Tip, charge pipe, downpipe and turbo off again.
The stud came out with some persuasion from a set of mole grips, and after the chopping down of some drill bits, the M10 conversion was underway. Here's one that was prepared earlier:
The metal for the turbo was similar to a firm cheese, so drilled out easily. After a bit of tweaking, studs were cut and fitted and some impressive welding was done by Ben to get the wastegate back in it's rightful place. Bit more adjusting and the turbo was back on. The rest is pretty standard and it's all back together.
I now just have to find what appears to be a massive boost leak. Neither of us can feel anything blowing under the bonnet, but the car will not boost past about 9-10 psi, and you can hear the air escaping from somewhere as it comes on boost.