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Years ago when i was building modified rotary RX7 engines, i remembered successfully plugging an exhaust outlet on an engine with Epoxy Putty (it held....) when I put on headers...

On my 1983 240D now the problem is you know that small corrugated aluminum tube that runs between the exhaust manifold to the intake manifold and carries preheat to the EGR valve and isnt really needed...mine is cracked..and I cant replace it..can I plug the exhaust side hole (about 3/4 inch Diameter) with heavy duty epoxy putty--has anyone done this..?

83 240D ---Plug an exhaust maniifold with Epoxy Putty?.....

You are in luck... that may be possible.... for one thing diesels run much cooler than that Rotary....
But you may also be able to use a Silicone ... I have seen them available with heat resistance which would allow casting Bronze into them... and them still be flexible to take bend off the item and reused...
But in general I never recommend JUST epoxy for anything... if you use it I would suggest backing it with something like thin brass sheet ( I use brass 10 thousandths shim stock )... much stronger and it gives uniform support when placing the epoxy....
On an exhaust you can use a screw type hose clamp to hold the brass in place... but remember to leave the epoxy as thick as reasonably possible...
Like many jobs.. cleanlyness is very important.... and do not start engine or touch it for at least 24 hours from placement....

Carrameow: are those D24s on your webpage?

To keep on topic: I hear JB Weld CAN work wonders. If it's cracked now, what's the harm?

Mike

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87 300D 178k (Crazy in the head)
82 Volvo 160k 240GL Diesel