I just got a 240D. Call me cheap, but has anyone found a cheaper way to block the exhaust and intake ports after removing the egr? I already bought and installed two kits (very satisfied, btw) for my two other cars, but I'd rather spend $28 on some brake pads or something, plus not have to wait for the "next batch" of the kits.

For example, instead of the copper disk method, or the silver soldering method, what if I just used a hacksaw/sawzaw to cut off the corrugated part, and blocked it up with normal solder (left over from some copper pipe work) any a suitably sized piece of steel?

On the intake part, what if I found a piece of steel roughly the same size as the opening, drilled holes, and screwed it on?

Any comments you have would be much appreciated.

__________________
J. S. Park

'82 240D Manual 240D (sold)
'83 300D-T 230k (sold)
'84 300D-T 118k (sold)