To do a good job with a dremel take about an hour . Take your time with the porting . You do not want to slip with the dremel and scrape the face of the wastegate opening where the flapper seats or you will leak boost through it all the time .
afpdl - what kind of tools would I need to take it off? I've never done anything like this (plus I don't have a dremel) so I think I'm going to take the turbo to Batlgrounds in Atlanta, and let them do it. I figure if they can cram an RB26 into a 350Z they can do a good job porting a wastegate.
I borrowed a TD04 from a friend (Pardon me, could a borrow a cup of turbo?) and sent mine off to Deadbolt. Top notch work and no more creep. A turbo can be taken off in under 20 minutes if you've done it a few times. Putting it back on can take 45 minutes to 4 hours all depending on 2 things: that F-bombing lower part of the oil return line on the metal stem and the IC piping omn the flanges. I might just get a FMIC so I don't have to look at hose darn pipes again.
My friend does alot of aftermarket work on the side. He's an STi mechanic at my dealership. It took him about an hour and a half to take off the turbo, port the wastegate and reinstall it. He works like a machine though.
To the average mechanically inclined person I'd estimate ~2-3 hrs to do.
I think ~25-35 minutes was spent on the porting.
Definately cured my boost creep. WOT 1-6th gears in 5 degree weather on an empty highway. Boost peaked at .11mpa
If anyone lives nearby, he does installs and wastegate ports if anyone needs it!