Let's start with the hard part: how do I extend the EGR tubing. The original tube is stainless steel. I would need to get more tubing and bend it into the shape to run along the head. Then, it would need to be flared for the compression fitting. Sounds easy enough but I cannot weld SS and have no means for bending and flaring. The other thought would be to relocate the fitting. If i were to relocate it closer to the tube's end I would have less fabrication to do. I wanted to weld on the fitting right to the header in the desired location but was told that the cast iron might crack later. Threading a new hole also did not promise much durability since the walls of the headers are thin and would not provide enough threaded surface. Also finding the 18mm tap would be a fun hunt on it's own. So I have resorted to maintaining the current positions of all the involved parts and running the flexible tubing.
This is 5/8 ID stainless steel flexible tubing that I got from B & B Specialties. Originally I thought it could be welded right on to the current tube. The trick would be to use a thick enough washer that would fit around the thin tubing and would allow for the proper weld to form. I even got myself a few of the large size lock washers. However, my friend was not confident in the weld being quality to have a proper seal. He offered to braze it with brass. I have never heard of the technique but he assured me that it's the best quality seal and will withstand the heat of exhaust gases.
This is how the finished product looks like. Mean while I had a chance to spray paint the headers too.
They look absolutely horrible but are not so bad parts. Apparently they flow as good as some of the shorties out there. In addition, I did some work to port them. But the reality is, since I am sticking to cats, my entire exhaust looks like ... ( i could only put a "bad" word here). Let's make it's best.
I did the same for the cats too.
After all was done, the parts went back onto the motor. Here's the shot of the head with the original bracket holding holding the tube in place.
The routing of the tube was a bit hard. I could not find enough space to make it clear everything.
So now the oil filter is in the way. Oh well, I was planning on relocating it anyways. Note that it's not necessary and FactoryFive does not relocate the oil filters on 4.6 motors. I am doing so because I want to and I have some cheesy excuses too: EGR tube is touching it, easier access for oil changes, relocation kit looks cool, blah blah blah.
For now I left the tube unsupported but I will be using steel wire to secure it to the exhaust header. Later I am planing to wrap the exhaust blanket around all this ugly to ensure that (a) I never have to see it again and (b) to keep the heat from slow roasting our legs in the foot boxes. I got these from Jegs in the mail.
Hmm. what's next?
