EGR delete by welding cooler - Ford Powerstroke Diesel Forum
6.0L Performance Parts Discussion What has or has not worked for you?

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post #1 of 15 Old 02-14-2013, 01:25 PM Thread Starter
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EGR delete by welding cooler

Phoning around trying to get a good price quote on an EGR delete kit install when one shop said this. What he said is that the job I'm wanting on getting done is taking some support from the y-pipe and sooner or later it will crack. What he's done in the past is take the cooler out and get it professionally plugged & welded. I hope I explained this correctly and what do you think? He said welding it up is cheaper as most of those delete kits are cheap junk. Thanks again for all the org help!!

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post #2 of 15 Old 02-14-2013, 01:35 PM
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The y-pipe is supported by its connection to the turbo and sits on top of the manifolds. The egr cooler connection doesn't support a damn thing, and if it did..that would lead to cracking the egr cooler or cracking the intake manifold where the egr cooler connects to it.
I bought/installed the cheapest of the cheap egr delete kits and have 0 issues with it over the 3 years it has been installed.
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post #3 of 15 Old 02-14-2013, 01:39 PM Thread Starter
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Thanks NYC. I hope I understood the mechanic correctly and wrote my question down on the forum correctly also. He was insistent that when you delete the system some pipes in the back were prone to cracking. What about getting the cooler welded up then? Is that a good option or go big or go home and do the full proper delete?

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post #4 of 15 Old 02-14-2013, 03:10 PM
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i do work on these all the time and i honestly though exactly what NYC was saying until i kept crackin y pipes. after my 3rd set i said i had enough and put the delete pipe in that comes with the sinister kits and low and behold i didnt crack another one. im not saying this is true on every truck as ive done muliple egr deletes and never had a problem but for some reason there are trucks that like to crack them. getting it welded isnt a bad idea esp if you live where they atleast check under the hood during inspections. personally i like the full delete because its cleaner looking but there is nothing wrong with welding it up

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post #5 of 15 Old 02-14-2013, 03:54 PM Thread Starter
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Originally Posted by rdunagan View Post
i do work on these all the time and i honestly though exactly what NYC was saying until i kept crackin y pipes. after my 3rd set i said i had enough and put the delete pipe in that comes with the sinister kits and low and behold i didnt crack another one. im not saying this is true on every truck as ive done muliple egr deletes and never had a problem but for some reason there are trucks that like to crack them. getting it welded isnt a bad idea esp if you live where they atleast check under the hood during inspections. personally i like the full delete because its cleaner looking but there is nothing wrong with welding it up
I wonder if Sinister has a slightly smaller o.d.

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post #6 of 15 Old 02-14-2013, 05:05 PM
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Welding up the cooler works just fine. We have done several over the last couple years, with zero problems. The delete kits that plug the oem up pipe are more prone to crack the bellows, but not always. If you go with welding up the cooler have the craftsman doing the work to do away with the scoop inside the up pipe where the cooler clamps on.

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post #7 of 15 Old 02-14-2013, 06:00 PM
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Originally Posted by Dene2006 View Post
I wonder if Sinister has a slightly smaller o.d.
I dont believe the dimensions are different other than the lack of a flange for the cooler.

Saying that though when I ran a 6.5 detroit a few of use were actually welding washers in the end of the uppipe to increase velocity to the turbo to decrease spool time and it worked fantastically.


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post #8 of 15 Old 02-14-2013, 06:48 PM Thread Starter
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this is one of many kits advertised on eBay. It is supposed to be easy to install and the auction says the intake doesn't have to come off. Can I choose to not use the up-pipe with this kit?

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post #9 of 15 Old 02-14-2013, 07:55 PM
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If i could figure out how to post pics i could show you but not real good with computers.I have done around 15 of these types of deletes they work good expecially if you have a visual with emissions testing.Havn't had any problems with this kind of delete, almost all of these were on 03 & early 04 trucks most guys with later model trucks want the up-pipe replaced because of the scoop inside.I know i won't delete the egr cooler without replacing the up-pipe because of the bellows cracking.

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post #10 of 15 Old 02-14-2013, 08:01 PM
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That kit doesn't have the plug for the factory up-pipe you would have to buy a plug or have one made.no the intake doesn't have to come off just loosened up so you can get cooler out from under manifold.That pipe isn't that hard to install just takes a little extra time

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