I want one too.

Any new progress here? I actually bought enough material (1/4" aluminum stock) for around 20 and gaskets for about 8 of these at one time. I kept the first one and may be selling the other ones if I figure out an easy method on making the exhaust side without ruining the pipe or leaving it tact. I think I may have a version which will work and isn't to bad to make, should know in a short while how it works. On the first kit I used 20ga steel which is a PITA to bend like I did, but it is sealed. My second kit I tried 24 or 26ga aluminum which is a lot easier to make but still pretty strong with the bend in it.

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Jeff M.
Mercedes W123 DIY pages are now located here.
1983 / 1984 300D Sold
2000 CLK430 Cabriolet ~58k Sold
2005 Avalanche 4x4 ~66k

I'll take two set when this is done.

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Never a dull moment at Berry Hill Farm.

We're waiting on price quotes at the moment. What is the thickness of 20, 24, and 26ga sheets? I don't know what the "gauge" number is for my disc, but it's about 0.50mm thick (give or take a few hundreths...)

Jeff - btw - do you have any photos of the plate you made? Is it milled?

According to some site I just found,
.50mm=24ga

I'd say the 24ga material looks about the same as what the factory used for the pipe. I'm not sure if I have a picture of it or not but it should be no problem getting one. No I didn't mill the part just cloned the gasket, used an angle grinder to cut rough shape, ground down the edges to finer shape, drill pressed the holes, and smoothed out the edges with a hand file for a finished product.

I actually spent way to much time on the one below, I got a lot smarter on my more recent ones using two factory edges so much less cutting, which is less possible error. The most recent one I also polished up a little bit which makes it even nicer than just the factory bar stock look.

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Jeff M.
Mercedes W123 DIY pages are now located here.
1983 / 1984 300D Sold
2000 CLK430 Cabriolet ~58k Sold
2005 Avalanche 4x4 ~66k

You can see the evidence left by the other leaking EGR plates, I'm pretty sure this one is sealing perfectly though.

Attached Thumbnails

 

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Jeff M.
Mercedes W123 DIY pages are now located here.
1983 / 1984 300D Sold
2000 CLK430 Cabriolet ~58k Sold
2005 Avalanche 4x4 ~66k

OK, we have the info needed to manufacture and provide the EGR blocking kits. The kit will consist of the following items:

1) Intake plate made from .125 stainless steel. (See Dave's photo for example, however, Dave's is .250 aluminum)

2) Exhaust plate made from .020 stainless steel. (See Dave's photo and sketch for example)

3) (2) Stainless 8mm socket head cap screws for intake plate.

4) Gasket for intake plate.

I can get a decent price on a set of 30 of these things by making them on a laser cutting machine.

The total for all of the above, including package and shipping will be $30.00.

Before I go to the effort of designing them on the laser machine and testing the .125 intake plate (Dave's was .250) and the new exhaust plate in stainless (Dave's was not stainless), I would like to know if 29 additional people are interested. And, if by some miracle, more than 29 people reply, then the price will go down to $25.00.

Rather than clog up the thread, just shoot me an e-mail at hpcs@csi.com. If I get 29 replies, I'll get them made and tested.

I might consider a kit but I looked at the EGR valve on my 300D and it looked like it would be a bit of a PIA to get it off. The bolts that attach it to the manifold looked hard to get to. So for now I'm using a BB in the vacuum line to diagnose its operation.

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DJ


84 300D Turbodiesel 190K with 4 speed manual sold in 03/2012

Maybe the cali version is harder but the federal I have was cake uninstalling (for cleaning of course).

Wow Brian do you work for that show on TV, CSI?!

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Jeff M.
Mercedes W123 DIY pages are now located here.
1983 / 1984 300D Sold
2000 CLK430 Cabriolet ~58k Sold
2005 Avalanche 4x4 ~66k

I could get a price at our shop to laser cut the intake part.
Why does it have to be stainless/alum would'nt plain steel work?
I would need to know the length & width also from the drawing

I say check on your guys Guage and ask them about prices for set up fee, total # needed to beat Brians price, and check out some of the quality of stuff they have done before. THEN...... as a group lets decide which machine shop to go with. We all loose out if the ranks of who want the blocking plates gets split between two or more machine shops. If that happens no shop will reach enough orders to ever get the product made at a reasonable cost. Another words.... its one shop product only or none ever will be made.

make since?

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"If anyone knows other lessons I need to learn, please tell me. I'm tired of learning them the hard way".
by JerryBro

The Glow Plug Wait: This waiting period is a moment of silence to pay honor to Rudolph Diesel. The longer you own your diesel the more honor you will give him". by SD Blue

My normal daily life; either SNAFUed- Situation Normal... All Fouled Up, or FUBARed- Fouled Up Beyond All Repair

62 UNIMOG Camper w/617 Turbo, 85 300SD daily driver- both powered by blended UCO fuels

If the shop can laser cut the intake plate, then they can laser cut the exhaust plate as well. The intake plate does not have to be stainless, but, I think everbody will be happier two years from now if you do use stainless. If you use aluminum, then you are probably forced to go to .250 thickness. This is more difficult for the laser and adds to the cost.

hi guys im just wondering, what's really the benefit of blocking the egr? i really have no idea...

Mike,

EGR stands for "exhaust gas recirculation" which is a system that allows some of the exhaust gas to be "recirculated" back into the combustion chambers to go around a second time. This serves to cool off the chamber and cut down on NOx emissions. It also serves to create additional soot and affects the driveability of the vehicle. Most of us have simply plugged the vacuum hose to prevent the EGR valve from operating. The valve is a rather big and ugly thing at the front of the engine, and, what we are trying to do in this thread, is to remove the valve completely and cover the opening with a custom stainless steel plate. We also need a cover for the pipe that sends the exhaust over to the valve.

Yeah there a bracket in the way that has to be removed plus the pipe from the EGR runs to the OX CAT. It looks like it would be more involved than just blocking off the EGR at the intake manifold.

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DJ


84 300D Turbodiesel 190K with 4 speed manual sold in 03/2012