i havent seen anything like this idea done. i was gonna buy a egr block off plate but i have an extra egr valve laying around. so my idea was to take a hack saw to this beast, and make my own somehow. what do u guys think. i was first gonna pull/cut the diaphram off and go from there. i just dont know how im gonna block it off, unless i filled the holes up with welds.

How about tracing the outline of the EGR gasket onto a piece of sheetmetal. Then cut the sheet metal out and use that as the block off?

Sheet metal would have to be thick enough to be rigid, but hacking up an EGR valve and winding up with something that still has holes in it doesn't jive with me.

Just a thought.

S-D

thats kind of what i thought. how thick do you think the sheet metal should be?

I would shoot for 18 ga. (~0.0478" thick). I used stainless of this ga. for a fuel pump cover and it is working well. I would error on the side of thicker, rather than thinner. If no 18 ga. is available, 16 ga. would work also.

All you need is a tiny chunk- a local sheet metal shop might give it up for free if they have small scraps.

S-D

alright. thanks for the help guys.

How about welding the underside of the valve after you've decked it.

Looks like an EGR, can be left on the car, pass visual inspections... and works like a block-off.

This is almost not fabrication enough to be in the fabrication forum. Get a length of 1” or 1-1/4” x 1/8” steel at the hardware store, cut it to length, drill the holes spaced the right distance apart, grind the edges to shape, paint… done.

Don’t use aluminum unless it’s a fairly heavy piece, I’ve seen them melt.