to all EGRless people!

[quack]

hey all,

im in the process in adding a top mount inty to the 2.8 mu.

so the first steep will be to remove the egr setup, im just wondering if someone(s) could give me the dimensions of the intake and exhaust plates that they made up for it.

also did you use the bolts already on it or did you buy more? also what size were they?

the total length, width and the distance between the mounting holes would be great

im using 5mm alu for the intake and 5mm mild steel for the exhust.

its just that i have to make them at work and would rather have all the bits ready for when i take it off.

thanks for the help in advance

[geeves]

Just about every exhaust Ive seen was done with a simple cut squash and weld. Its not visable and saves a lot of dismantaling. The best inlet Ive seen used 2 plates each cut using a egr valve as a template. Take a valve off and make a cardboard pattern then reasemble till you make them. Make new gaskets from gasket paper instead of using the original metal gasket and use 10mm aluminium. 5 mm will work but 10 means the bolts will be the right size. 5 might also warp.
Mine was done by a mechanic before I bought it but its rough as. A rectangle of 4mm alloy cut with tin snips. 3 months after I bought it the metal gasket started to leak. Above 80kph or any hill was accompanied by a squeal you cant belive.Paper gasket fixed and 10 years later still going strong

[pig75]

This might help 8mm holes for the inlet and 10mm for the exaust
[

edit original sizes were wrong all fixed now

[quack]

yeah i would do that but i dont have a welder, nor know have to use one:( so a simple plate will work the same.

i want to try make the plates before i take it off so i can do it in one go, as i can only make the plates at work.

what do you mean by 10mm and 5mm? do you mean the lengh of the bolt? what is the size of them? i think they look like 10mm?

would the 2.8 be the same as the 3.1? because i have got the messurments for the 3.1, my trucks in the shop at the mo so carnt measure mine.

[quack]

hey thanks pig75 exactly what i was after!

when i have the finished product i will post up some pics

[Jimmu]

I just bolted one of the flanges from the EGR back on and plugged the holes... Dodgy but it works.

Jimmy

[fatso]

If Pig75's drawing is correct, this should print to scale, but I haven't checked it yet. Thanks for the dimensions

rapidshare.com/files/22082511/egrblank.pdf.html

[pig75]

That link don't work

[geeves]

It does work but theres a trick to using rapidshare.
The link takes you to a option page where they try to con you out of money. At the bottom is the free option. You then get a choice of mirror sites to actually download the pdf from. You need to enter the randomly generated security code. Then it works very well. Ive run into rapid share before for some of those other types of video clip
The plates look right but I dont have the measurements to compare it too

[pig75]

I just printed the drawing out. it's so close.
Hole centres for the top one measure 54mm and the second one measure 41mm. I have A4 paper

[fatso]

Try this one for A4 paper. We only half use the metric system over here so I don't have any paper that size to test it. I also changed the height of the 2nd plate 'cause mine needed to be smaller. I made the plates today to this drawing but I haven't checked if they fit. On my engine it looks like both plates use 8 mm bolts so a 9mm drill would clear.
www3.telus.net/jlh140/egrblankA4.pdf

Alternately don't "fit to page" and it should print correctly regardless of paper size.

[pig75]

Perfect fit with the fit to page turned off ;D and only about 1mm with it turned on. I think the admin should put that PDF in the workshop section

[caffa]

WOWWEEWOWWOW !!! I agree ... That .pdf rocks .... Very well done.