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Discussion Starter #1 (Edited)
When I popped my head gaskets, I wanted to do something about the EGR to prevent this from happening again.

With the emission testing in mind. I decided that I wanted to keep the factory look. So that emission testers can not tell if your EGR system has been modified. Also the EGR valve has not been touch. No codes have been thrown out, even with a tuner. Also my tunes are not set up for egr disable.

To date, I've been running this system on my personal truck for almost a year with zero problems. This includes pulling a 11,500 lb. fifth over the passes in Washington state many times. My Egt's never went over 1200 degrees, and my engine coolant never went too hot while pulling on long steep passes (6+ percent grade). I'm not easy on my own equipment.

The welding procedure is tig, and the material is 304 Stainless Steel.

EGR Delete 002.jpg

EGR Delete 010.jpg

EGR Delete 014.jpg
 

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subscribed, will check out when i get home
 

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Discussion Starter #4
I'm reading some of the posts on here about the EGR problem. That people are willing to blow $400 to $900 (I just seen one for that price. :tard:). That just surprises me.

But hey, I didn't waste that much $ on mine. :hehe:
 

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how much

how much do you charge to weld mine,or where is yr work being sold at. I take it that you live in the northwest,I live in Portland
 

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I'm seriously thinking about getting this done, One question the Bank Big Hoss system is what I'm probably gonna go with as soon as my warranty expires. If I get that or any super chip, will your work interfere with it.
 

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This approach blocks off the exhaust from the cooler, but leaves the EGR cooler in which the coolant still flows, correct?
 

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Discussion Starter #8 (Edited)
I'm seriously thinking about getting this done, One question the Bank Big Hoss system is what I'm probably gonna go with as soon as my warranty expires. If I get that or any super chip, will your work interfere with it.
This wouldn't interfere with any tuner, chip, or otherise. In fact I run a tuner that the egr system is still functioning, I haven't thrown any codes at all. I'm running the exact same set up in my personal ride. It's pretty solid.
 

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Discussion Starter #9
This approach blocks off the exhaust from the cooler, but leaves the EGR cooler in which the coolant still flows, correct?
That's correct.

I blocked off the up pipe as seen. Than I seal welded both ends of the cooler to prevent any coolant leaks into the intake or otherwise. I set it up this way to pass the smog inspectors in case if they decided to do a visual inspection. I know for a fact, that if they do an visual inspection and the EGR system is absent. They will fined you and make you reinstall the comlpete EGR system out of your pocket.
 

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I like this set up. I am in Eugene, OR. Can you PM me a number I can reach you at? I would like to do this sometime this winter.

Donnie
 

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Discussion Starter #12

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Discussion Starter #13
I like this set up. I am in Eugene, OR. Can you PM me a number I can reach you at? I would like to do this sometime this winter.

Donnie
PM sent. :thumb:
 

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I am looking to do this very thing, still no codes or problems? This looks like the exact fix for my truck if it is not throwing any codes.
 

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what about exhaust back presure when the egr valve opens its takes a certain percent of exhaust back presure away with it blocked and the valve open and no presure drop in exhaust. im not to sure how to explain it but your engine presure will be out of balance and either there will be a power loss or blown head gasket. egr opens, mainifold presure is looking for the increase back presure looking for decrease. the 6.0 is like a seesaw needs the same presures one both side to stay in balance. does your turbo boost fluctuate?
 

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what about exhaust back presure when the egr valve opens its takes a certain percent of exhaust back presure away with it blocked and the valve open and no presure drop in exhaust. im not to sure how to explain it but your engine presure will be out of balance and either there will be a power loss or blown head gasket. egr opens, mainifold presure is looking for the increase back presure looking for decrease. the 6.0 is like a seesaw needs the same presures one both side to stay in balance. does your turbo boost fluctuate?
I'm not to sure how this would be any different than an EGR delete? If I block the up-pipe, egr cooler at both ends and leave the egr valve in place to complete the electrical loop. I need all the info anyone has on this cause I don't know.
 

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ive done 6 trucks the same way but i use a 555 025 and a 555 021 dorman steel freeze plug and mig weld them then pull the egr and spot weld it closed got over 50000 on a couple of em no problems takes 3 hrs cost 2 bucks
 

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Discussion Starter #19
I've been running this set up for sometime without any problems. Towing heavy (12,000 lbs. trailer) regularly for the last two years. All the materials used in this modified egr setup is 304 stainless steel, not carbon steel. Stainless steel is better at higher heat than the carbon.
 

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Discussion Starter #20 (Edited)
Just got new pictures.
 
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