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Diy egr block off advice - Printable Version

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Diy egr block off advice - Dark Hawk - 02-28-2016

I am planning on blocking off the egr on my 1984 300d by making my own plates. Do I just need to cut a piece of aluminum info shape, drill the holes, and rtv a gasket or is it more involved? Any advice is appreciated including where to buy a prepaid kit because I looked but could not find one. Thanks.

RE: Diy egr block off advice - Alec300SD - 02-28-2016

Contact Rollguy.

http://www.peachparts.com/shopforum/diesel-discussion/355250-sale-egr-delete-block-off-plate-kit.html

Cash only as I recall.

RE: Diy egr block off advice - MFSuper90 - 02-28-2016

It is as simple as what you described for the intake. For the exhaust I cut the stock flex pipe and has a friend tig weld a washer on it and just clamped it back onto the manifold. It also makes a good port for exhaust backpressure if you are interested in performance Smile

RE: Diy egr block off advice - Torkey - 02-28-2016

(02-28-2016, 05:37 PM)Dark Hawk I am planning on blocking off the egr on my 1984 300d by making my own plates. Do I just need to cut a piece of aluminum info shape, drill the holes, and rtv a gasket or is it more involved? Any advice is appreciated including where to buy a prepaid kit because I looked but could not find one. Thanks.

I've got a manifold I could sell you with the EGR blocked.  It also has been ceramic coated.  PM me if you are interested.

RE: Diy egr block off advice - zeeman - 02-28-2016

(02-28-2016, 05:37 PM)Dark Hawk I am planning on blocking off the egr on my 1984 300d by making my own plates. Do I just need to cut a piece of aluminum info shape, drill the holes, and rtv a gasket or is it more involved? Any advice is appreciated including where to buy a prepaid kit because I looked but could not find one. Thanks.

Intake is just a plate bolted on and silicon as stated already. I tap the exhaust port to a pipe thread and screw in a pipe plug in. Also you can also drill and tap the pipe plug for a EGT temp sender.

RE: Diy egr block off advice - Dark Hawk - 02-29-2016

Thanks for all the good advice! I like the variety of responses.

As for the tig method, if only I could afford a tig welder Sad love tig welding.

I will pm that guy over on peachparts, thanks for the link.

For the threaded pipe method, I like this one too and is more tangible and I really like egt temp tap idea, that's clever, easy, and clean way to do it. What size tap do I need? I don't want to buy a whole set being that I don't have much use for them and it is kind of hard to figure it out without a set on hand in my limited experience with taps. 

As for the manifold, I might be interested if it's ported and polished. Otherwise I'll pass, but thanks for the offer.

Thanks for all the great responses, I appreciate it.

RE: Diy egr block off advice - baldur - 02-29-2016

TIG welders are ridiculously cheap out of China these days. A compact DC unit with HF start for welding steels will run about a couple hundred USD. I picked up a 250 amp AC/DC unit late 2014 for $500.

RE: Diy egr block off advice - Tito - 02-29-2016

I use a 200 dollar TIG welder. It hasn't let me down and is good bang for the buck. Especially for beginners like me!

RE: Diy egr block off advice - MFSuper90 - 02-29-2016

It's not a good location for the egt sensor as it is not in the mainstream exhaust.i guess it might be better than nothing, but the way I look at it is if I'm going to spend $100+ on a egt guard I'm gonna put in it the right spot haha

RE: Diy egr block off advice - EmJay - 03-01-2016

I'm more interested in the thread the EGR hole with a plug, but who knows the size? Agree, gauge close to turbo

RE: Diy egr block off advice - Alec300SD - 03-01-2016

(02-29-2016, 01:06 AM)Dark Hawk Thanks for all the good advice! I like the variety of responses.

As for the tig method, if only I could afford a tig welder Sad love tig welding.

I will pm that guy over on peachparts, thanks for the link.

For the threaded pipe method, I like this one too and is more tangible and I really like egt temp tap idea, that's clever, easy, and clean way to do it. What size tap do I need? I don't want to buy a whole set being that I don't have much use for them and it is kind of hard to figure it out without a set on hand in my limited experience with taps. 

As for the manifold, I might be interested if it's ported and polished. Otherwise I'll pass, but thanks for the offer.

Thanks for all the great responses, I appreciate it.

Best place to mount an EGT pyrometer probe is right before the turbo in the middle of the exhaust stream to get accurate temps.
A blocked-off EGR port does make an excellent place to mount an probe to monitor exhaust pressure.

The tap needed depends on the probe you use. Ceramic coating is nice. Porting is probably not needed. For a clean look nothing beats an early non-EGR manifold setup.

My 78 W116 300SD came with non-EGR exhaust and non-EGR intake manifolds.

Installed the spare ceramic coated exhaust manifold back in 2014 (more photos and write up in link on post 46 and 47).
http://www.peachparts.com/shopforum/diesel-discussion/350473-my-new-1978-300sd.html
Just sold my original non-EGR exhaust manifold to a forum member.
Still have the original non-EGR intake manifold (log-style) mounted on the car.
That intake manifold will be available for purchase later (cheap).

Next step, preparing and installing the W115 long runner intake to allow for an intercooler and piping.
Intercooler and piping to come after new Dieselmeken 7.5 mm elements for MW pumps are available.
(Coming in a few months as per his 2-23-2016 Facebook post Big Grin ).

Sorry about the large photos. Click on them, then select 'Open image in new tab' to see a more manageably sized photo.

   

RE: Diy egr block off advice - MFSuper90 - 03-01-2016

I have a complete P&P head and manifold set that I would think about letting go. I would even block off both egr ports for you.
The way I block off the exhaust side is completely cut the egr port off of the Manifold and weld the port shut, because if you are planning on going with a larger turbo the intake will hit the egr port. Plus it looks nice Smile

RE: Diy egr block off advice - zeeman - 03-02-2016

(02-29-2016, 01:06 AM)Dark Hawk Thanks for all the good advice! I like the variety of responses.

As for the tig method, if only I could afford a tig welder Sad love tig welding.

I will pm that guy over on peachparts, thanks for the link.

For the threaded pipe method, I like this one too and is more tangible and I really like egt temp tap idea, that's clever, easy, and clean way to do it. What size tap do I need? I don't want to buy a whole set being that I don't have much use for them and it is kind of hard to figure it out without a set on hand in my limited experience with taps. 

As for the manifold, I might be interested if it's ported and polished. Otherwise I'll pass, but thanks for the offer.

Thanks for all the great responses, I appreciate it.

I used a 3/4" pipe tap, the castings vary some so you may have to take a die grinder and round out the hole for the tap. It doesn't seem to affect the temperature very much in that location.
The problem is that the sender probe is long and doesn't fit well anywhere else.

RE: Diy egr block off advice - Dark Hawk - 03-05-2016

I'm just going to fab up my own kit and save a few bucks. I'll get around to it once I order my egt gauge.

RE: Diy egr block off advice - AlpinaM30B35 - 03-05-2016

For the 603 manifold a dorman 21mm freeze plug works perfectly to plug the EGR hole

http://imgur.com/E9SVNb7

RE: Diy egr block off advice - Simpler=Better - 03-06-2016

Good advice here on EGT probe, has to be in the path of the fire.

For the EGR, just unplug it-it looks like crap that way but doesn't cost anything Tongue

RE: Diy egr block off advice - Dark Hawk - 03-07-2016

This ain't Africa lol

RE: Diy egr block off advice - Dark Hawk - 03-07-2016

Wait what material is the factory header, iron? If it's steel I could just weld a plate over the exhaust portion.

RE: Diy egr block off advice - MFSuper90 - 03-07-2016

It's cast iron. I've successfully MIG welded cast several times, or you can braze it.

RE: Diy egr block off advice - Simpler=Better - 03-08-2016

(03-07-2016, 06:59 PM)MFSuper90 It's cast iron. I've successfully MIG welded cast  several times, or you can braze it.

x2 it's good metal, just preheat the crap out of it(charcoal grill), weld it, then put it back on the grill with the lid closed and let it cool down over several hours the first time.

Also hammer the weld right after you zap it.

RE: Diy egr block off advice - AlpinaM30B35 - 03-09-2016

I welded the euro 603 cast exhaust elbow to a 2.5" stainless v band without issue. Prepped it well, minimal preheat, 1/8 sharpened 2% thoriated, #7 gas lens at 12CFH, 309 filler

Worked great

RE: Diy egr block off advice - Dark Hawk - 04-13-2016

Made it! The intake manifold block off is a bit ugly but seems to function fine, I'll know for sure once my boost gauge is installed which I'll do later today. I made it like I said it would in my first post in this thread.

I have the exhaust porting bandaided for now, until I get a pipe tape and die which seems to be the best option for what I want to do.