weld the egr cooler ?? - Ford Powerstroke Diesel Forum
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Old 07-23-2009, 08:34 PM
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Lightbulb weld the egr cooler ??

I was searching for the best egr delete kit and found on a different forum, where a couple of people have just welded the exhaust in and the exaust out on the cooler. They stated that nothing can go wrong by doing this. they had pics of the job. It makes sence to me. Anyone have any objections to doing this? Its a lot cheaper than spending $500+ on a kit.
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Old 07-24-2009, 04:12 AM
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like anything something CAN go wrong.

i made my own kit, but my cooler is totally gone

Last edited by 03f250stroke; 07-24-2009 at 04:26 AM.
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Old 07-25-2009, 12:55 AM
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you dont even want to know how i did mine. i took the egr cooler out, got one of my 1/2 in drive sockets that fit perfectly in the cooler and welded the center of the socket to seal it, then welded the socket in the egr cooler and put er back on. coolant lines are still hooked up like normal and egr valve is still in. redneck style... free!
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Old 07-25-2009, 01:04 AM
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the best setup or the cheapest setup? cheapest isnt the best, but the best is far from cheap...

Adam at First Coast Diesel has a really nice setup but its not cheap... Elite Diesel is a really good one too, but again, not cheap.... Ragin Diesel and ITP Diesel sell some inexpensive setups that are good... but Direct Injection has the best by far... its like $1200 for his setup, but you will gain performance as well as getting rid of the EGR
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Old 07-25-2009, 01:17 AM
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dunes runner, whats your opinion on the way i did mine?
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Old 07-25-2009, 03:10 AM
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..ghetto
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Old 07-25-2009, 10:13 AM
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Originally Posted by jsr86 View Post
dunes runner, whats your opinion on the way i did mine?
um, you dont wanna know.... i'll just say I dont recommend it and it leave it at that
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Old 07-25-2009, 04:22 PM
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Originally Posted by crazyman25 View Post
I was searching for the best egr delete kit and found on a different forum, where a couple of people have just welded the exhaust in and the exaust out on the cooler. They stated that nothing can go wrong by doing this. they had pics of the job. It makes sence to me. Anyone have any objections to doing this? Its a lot cheaper than spending $500+ on a kit.
It's the route I'm taking. If the EGR is welded shut correctly on both ends then there is really no way left for it to fail. What could it do? Develop a hairline crack internally? Even if it did- add another quart of coolant and call it done. It's not like it's going to go anywhere...

You also maintain the advantage of appearing bone stock from the outside.

I don't blame the guys selling kits- it's a free market and their kits do work. I just personally don't feel the need to spend that kind of money when I can accomplish the same thing for way less and keep it stock looking to boot.

Just my 2 FWIW
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Old 07-25-2009, 05:14 PM
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i did consider doing it like you described, but deleted mine like the way they show in 6.0 mods on this site. not that hard to do.the only thing i really don't like about it is the rubber hose, but you can replace it very easy. also, my cooler was stainless steel, so you may want to consider tig welding it. but as long as you seal it up good and the outer shell dosen't spring a leak it would be fine. i also believe leaving the cooler in also helps support the exaust flex pipe going up to the y pipe too.
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Old 07-25-2009, 05:21 PM
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No question about it..... Bill speaks the truth. I hate to admit it, but even after the crap I just went through with my cat removal, the EGR delete kit is next. We appear to be big risk takers eh??? Ever notice the waivers on some of the vendors sites?
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