Well, if I didn't have to go for emissions testing I would remove the EGR system alltogether since I'll be using megasquirt.

Since I have to use the stock ECU for E-testing, w/out the egr line hooked up, the EGR valve takes in fresh air (instead of exhaust gas) and makes the engine run lean.....I think.

I tried out the '99 EGR line, cut it up and fabed up the piece to connect to the manifold; looks like ****, hits the dip stick and I'm not putting that by my pretty downtube. I'm going for the '01 EGR tube and the fitting from BEGi.

 

I used an NB manifold on my NA so I know what you're going through. I cut up my stock '97 EGR tube and a stock '99 EGR tube and basically used the bend from each to custom fab a tube that fit.

In your situation I'd weld the bung on the manifold as close as you can to the flange and do the same. Hack up 2-3 tubes to make one that works for your application. The tube is surprisingly thick so it's easy to weld.

 

Ok, just to finish off this thread for future DIYers:

I ended up using the '99 bung and ferrule from BEGi. By the way, Stephanie and Corky couldn't have been more helpful.

I extended the EGR tube ~ 1.5" and built up the manifold as I showed in the mechanical drawing on the first page.

Thanks for everyone's help!

 

Looks good, nice to have a tig torch in house to complete projects like this.

 

Good job. That's probably what I will do as well. That way I don't have to sweat the location of the bung.

 

Thanks, I'd be lost w/out my TIG.

One last note, I didn't cut a 1-1/4" hole in the runner, I welded the angular piece directly to the runner and filled in w/ a stick welder, then drilled the hole thru.