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Old 06-23-2008, 03:56 PM   #1
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Default Fabricating an EGR fitting on a 99 turbo manifold

First, some background: I've built a DIY turbo system for my 1999 (mostly), I live in Canada and need to pass emissions so I probably have to keep the EGR system.

So I'm a good way through my DIY turbo build and I'm trying to connect the EGR pipe to my homemade log style turbo manifold.

I bought an EGR fitting and ferrule from Corky at Bell, but it looks pretty difficult to get it in the right spot on the manifold w/out a lot of cutting.

The real problem is that the centerline of the EGR port is too close to the exhaust flange to weld the fitting in properly. I could get it to work if the port was an inch further away from the flange.

I think my only options are to either cut the EGR pipe and elongate it by 1", or to try and stretch it by taking bends out.

Anyone been down this road before?

I've attached a pic of the OEM location and what I want to do.
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Fabricating an EGR fitting on a 99 turbo manifold-egr-design.jpg   Fabricating an EGR fitting on a 99 turbo manifold-egr-picture.jpg  
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Old 06-23-2008, 04:27 PM   #2
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Isn't the 01-05 EGR tube compatible on the intake manifold side?

Because you could much more easily add the exhaust fitting for the 01 to the hotside. I did it on mine by hacking the EGR fitting off the stock exhaust manifold.

by the way, anyone want a mostly-complete 01 manifold?
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Old 06-23-2008, 05:24 PM   #3
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Originally Posted by y8s View Post
Isn't the 01-05 EGR tube compatible on the intake manifold side?

Because you could much more easily add the exhaust fitting for the 01 to the hotside. I did it on mine by hacking the EGR fitting off the stock exhaust manifold.

by the way, anyone want a mostly-complete 01 manifold?
I could buy the '01 egr pipe if it makes life a lot easier, but I already have the '99 bung.

what makes the '01 install easier? Is the tube longer so that the port is further away from the flange?
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Old 06-23-2008, 05:36 PM   #4
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Seriously, if you can fab the manifold, I can't see why you couldn't put the bung where you want it and cut and weld, bend, lengthen the tube to meet your needs.
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Old 06-23-2008, 05:43 PM   #5
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FWIW whatever you do be careful if you use the stock tube to get the location and angle of the EGR bung just right. It is hard enough as it is to get that tube in there when everything is in the right place. The EGR tube was the most PIA part of my BEGI-s install.
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Old 06-23-2008, 06:42 PM   #6
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Quote:
Originally Posted by fluke View Post
I could buy the '01 egr pipe if it makes life a lot easier, but I already have the '99 bung.

what makes the '01 install easier? Is the tube longer so that the port is further away from the flange?
kinda.

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Old 06-23-2008, 07:18 PM   #7
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Quote:
Originally Posted by Stein View Post
Seriously, if you can fab the manifold, I can't see why you couldn't put the bung where you want it and cut and weld, bend, lengthen the tube to meet your needs.
Well I wanted to know what others have done about this since I'm sure I'm not the first.
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Fabricating an EGR fitting on a 99 turbo manifold-egr-fitting-manifold.jpg   Fabricating an EGR fitting on a 99 turbo manifold-egr-fitting-manifold-2.jpg  
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Old 06-23-2008, 07:40 PM   #8
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Quote:
Originally Posted by y8s View Post
kinda.

WOW! COuld you use a -10 AN Male fitting instead? Would be nice if we could as I would pickup an 01-05 EGR tube in a second for my future build.
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Old 06-23-2008, 08:09 PM   #9
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Quote:
Originally Posted by y8s View Post
kinda.

Oh, no kidding; that looks much easier. Where did you get the fitting that you welded on? I don't have an '01 header to cut up :(
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Old 06-24-2008, 01:13 AM   #10
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Why not cut part of the EGR tube and mate it to a flexible pipe? This way you can mount the nippe on the manifold anywhere convenient.
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Old 06-24-2008, 01:16 AM   #11
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That EGR hardline is a PITA to bend i would try to get some small weldable pipe fittings like what you use for the manifold build. I bet with a 90 you could make something that worked. Might be ghetto though.
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Old 06-24-2008, 02:22 AM   #12
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Is there no such thing as flexible pipe that could be used?
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Old 06-24-2008, 08:22 AM   #13
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Quote:
Originally Posted by cjernigan View Post
That EGR hardline is a PITA to bend i would try to get some small weldable pipe fittings like what you use for the manifold build. I bet with a 90 you could make something that worked. Might be ghetto though.
Looks like this is the way to go.

Anyone know what the material is? Looks like stainless steel.
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Old 06-24-2008, 08:37 AM   #14
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I meant weld something to the manifold. If I was you and I was going to do this I would weld the ferule assembly to the manifold. Cut the hardline, splice it with copper tubing and braze it. Then i would slip a piece of a pop can (thin aluminum) between the egr tube flange and intake manifold because egr sucks.
It is stainless.
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Old 06-24-2008, 11:14 AM   #15
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1. EGR Hardline is stainless and mine is bent to ****
2. 01-05 EGR fitting is not AN or anything I could find easily
3. It must be sourceable since some shops make EGR compatible headers (RB, FM, maybe more). Probably one of those places could sell it to you?

Another option is to get a steel AN fitting and just cut and re-flare the EGR line.
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Old 06-24-2008, 11:20 AM   #16
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Quote:
Originally Posted by y8s View Post
2. 01-05 EGR fitting is not AN or anything I could find easily
I covered wife's stocker (01 mani) with a pipe cover nut (?) thingy from the plumbing section of OSH.

Quote:
Another option is to get a steel AN fitting and just cut and re-flare the EGR line.
I tried cutting and reflaring, and the flared end cracked a bit.
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Old 06-24-2008, 04:03 PM   #17
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Ok, I just confirmed w/ Stephanie that BEGi can supply the '01 weld on fitting for the manifold.

I think that the easiest solution is to buy the '01 EGR pipe and the '01 fitting and use that.

However, I've already bought the '99 bung and I cut up the '99 EGR pipe this morning and bought some SS tubing that fits over it, so I'm going to make this approach work.
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Old 06-25-2008, 11:34 AM   #18
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my egr pipe has been disconnected for about 1 yr now and no engine code yet. why not just leave it there without connecting it?
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Old 06-25-2008, 12:15 PM   #19
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On an NA? fluke's car is an NB.
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Old 06-25-2008, 07:26 PM   #20
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Quote:
Originally Posted by jasonc Sbb View Post
on An Na? Fluke's Car Is An Nb.
Nb
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