Built an EGR cooler delete kit.
Okay, so not as many pictures as I would like since I was in a time crunch and pretty much just forgot to snap pics.
the coolant block off plates where made by cutting the old lines off, plug welding the holes, and then turning them in the lathe to machine them perfectly flat. they came out great for a total of 0 dollars and 30 minutes of work.
the exhaust block off plate was made by plasma cutting .250 321 stainless plate and using an oem ford egr cooler gasket with new stainless hardware.
the intake elbow was fabbed out of mild steel plate plasma cut then machined smooth, welded to a section of three inch mandrel bent tubing coated in high temp enamel.
(in retrospect the ones I make in the future are going to have a bung in the top for water/methanol injection and will be powdercoated or stainless.)
the dpf was the simplest part utilizing a completly straight section of 4" tubing that we welded bungs in for the sensors (couldnt figure out which ones to keep and which to get rid of, so just kept them all, easy enough)
Tuned with an SCT to ward off any check engine lights. I am insanely impressed with the truck now as I appeared to have awaken a sleeping giant.
I am looking forward to the next free weekend I have to start building some more things for the truck.