Need to weld the header

[Rusman]

Ok, I was wondering if someone can help me out here. As you know I got the BBK Headers. To keep emissions, I need to weld a bung on to the header for the EGR tube. The problem is that I can't weld, nor do I have access to the proper tools if I knew how :).

I first need to know what I need to get so it will fit properly, and secondly if someone could help me out with the welding portion. I can pay, provide beer, assistance with something you have going, or post several lists of mp3s to download.

I was really hoping to be able to do this this weekend, but of course beggars can't be choosers :).

Thanks!

[Rusman]

Nay has graciously offered to assist with the header welding, but I have to get all the parts (thanks nay!).

Anyone know what the size of the EGR fitting is? I'm still trying to get a stock header, but having some trouble and I can't really take mine apart since it's on the car :).

[Rusman]

I have talked to Houston performance and Steve stated he doesn't think the position of the EGR bung is no big deal. So that's good. I think I'd have a better time of custom making the EGR tube than trying to get the bung lined up exactly on the header.

I need to find out what fitting I need still, but I'm working on that. I'm also trying to get a stock header from HP as well for comparison, but he didn't think he had one but he's looking.

[Neighbors]

Cool Rusty! Just let me know and you're on!

Shouldn't take ten minutes or so...

[Blue91]

That's in "Neighbors-Time", which means an hour later, all will be perfect, the stars will be aligned, and there will be world peace. :blue:

[89LX306]

LOL @ Fred. You speaketh the truth my man. But of course Chris doesn't do exhaust work. I think he is starting to enjoy exhaust work.

[Rusman]

Jesus Christ. I still cannot find this damn fitting! A couple of muffler shops I called that knew what I wanted did not have them in stock. I was hoping to get the piece welded this weekend so I could have the headers coated and installed next weekend, but it looks like that isn't going to happen.

Oh well...maybe I'll be able to make the CCB this way!

[Rusman]

I've made a small advancement in my quest to make non-EGR headers into EGR headers by purchasing the EGR tube that goes from the header tube to the valve. Please refer to this link (http://www.rusman.com/cobra/egrtube/) for some really crappy pictures of the tube and ends. Sorry, but my camer is a POS. Who wants to buy me a better one? ;)

I forgot to mention that this thing just appears to be some ~1/2" (i.d.) tubing, flared at each end, with fittings on the end and bent to fit. I could probably make one myself.

[Neighbors]

Rusty,

That appears to be a standard 45degree flare fitting, common to AC systems, water/gas lines, and EGR(!), LOL!

This picture is the tell-tale :
http://www.rusman.com/cobra/egrtube/tube2.jpg

You have your stock tube, right? Cool! Now, if you find the need to make a new tube, it's a matter of finding some tube and making simple single flairsif need be...

Cart that stuff down to Neighbors Toxic Dump and Huff House, and we'll be glad to get all loopy and take care of it for you, for a small fee :D

Oh wait, I don't do exhaust work ;)

Nay!

[Rusman]

Ok, cool. I still need to find that fitting.
So, i can just stroll into Home Depot with that thing and say "i need a fitting to fit a 45* flare" and they will (hopefully) know what I'm talking about?

My goal is to make this car emissions legal. Once I find the fitting, it can be welded. Once the stuff is installed I can plug the EGR and run it that way for awhile until the tube can be fabbed.

Thanks Nay!
You're the best, I don't care what pRick says about you!

[Rusman]

Nay, I think I have struck out. I went to two hardware stores, Oreilly's, and Home Depot and came up empty each time. I'm beginning to think I'm doomed to not being emissions legal.

Two things left for me to try: get a set of old headers and cut the fitting off of it, and call MAC or someone else and see if they can sell me the seperate fitting piece.

I also want to call my friend who is a great fabricator type of guy. He'll probably know what I needand where to get it.

[Rusman]

/me continues the trend of replying to himself

I called a couple more places today, one of them MAC performance, and the other was a race shop recommended by a friend.

MAC, who sells their headers complete with EGR fittings, do not have the capability to sell them individually. The guy (TEX...yeeehaaawww hehe) was very very helpful, but at first thought I wanted an O2 fitting. No :( I wish it were that easy. After giving me the bad news, he did offer to look more into getting me the correct fitting.

The race shop (ORC - 713-647-7011 ask for Bobby Humphrey) said he knew what I was talking about, but normally didn't handle that kind of work so he couldn't help me. He did refer me to B&B Tire on Hempsted @ Blalock. Tim @ B&B also knew what I wanted, but didn't have it either. He thinks he might be able to get it, but I am going by there in the morning with the EGR tube I have from Tommie Vaughn so he can look at it.

I did have a thought, Nay. If these avenues come up bust, again, what do you think about AN fittings and braided steel line? Would that work or would it create a melted mess all over my headers? Here's an image of the first fitting I found that is close.
http://www.rsracing.com/rscatalog/images/617-6041.gif

[Neighbors]

Rusty,

What size thread is that? Can you measure it and let me know?

What about cutting one out of a salage yard vehicle?

Nay!

[Neighbors]

http://www.svtlightnings.com/svt/headers/Img_0026.jpg

http://www.svtlightnings.com/svt/headers/Img_0033.jpg

http://www.svtlightnings.com/svt/headers/Img_0034.jpg

...the whole thing here (http://www.svtlightnings.com/svt/headers/header.html)

"7. Remove the E.G.R. fitting from the driver side manifold. It may be necessary to heat the fitting and surrounding in order to extract it, depending on how old the vehicle is and the condition of the factory manifold. Because the fittings are sometimes very difficult to remove, It may be necessary to replace it with a new one from Ford. The part number is N801906-S51 for trucks, and N801905-S51 for vans. Check with the dealer for the proper unit." For Ford trucks!

http://www.eurekaboy.com/borla.htm

<hr>

If'in it were me, I'd go get a fitting from a Litening or F150 that fits the tube you have from Ford...

Take ten minutes, add Google, blend, and voila'! :D

[Rusman]

I love you Nay! :)

I'll check with Ford tomorrow and see what they have.

As for your other post: How would I measure it?
/me is ig'nant in this respect

Cutting one from a salvage yard would work. There's a guy in Willis (where's Willis? Whatchoo talkin bout Willis!?) who said I could have his stock headers.

[Neighbors]

Well, get up to Willis then, LOL! That would be the easiest way to do it, and we'll reuse your fitting at assembly...

[Rusman]

Just checked, it's 50 miles one way to Willis.

Gotta see if I can get this guy to meet me anywhere, otherwise I'll be driving to Willis sometime this week.

[Blue91]

Originally posted by Rusman
Just checked, it's 50 miles one way to Willis.

Gotta see if I can get this guy to meet me anywhere, otherwise I'll be driving to Willis sometime this week.

He can drop them off here, if he's willing to. I can just get them to ya this weekend. Ask him if that's ok. I could meet him at 1960 and 45.

[Rusman]

Thanks fred, but seeing as how he's giving these to me, I don't want to overstep his generosity. I'll mention it to him though. Maybe he works in Houston, or closer than Willis.

[Blue91]

Who is it? Anyone we MIGHT know?

[Rusman]

Dunno fred. His first name is Jimmy, and I think he's only had a couple posts on WSM.

Good news though! I talked to him just now. He's at the Woodlands Mall and I'll be heading up there to meet him in about an hour. Hopefully I'm not jinxing myself :(.

w000000t

Nay, you ready for some exhaust work this weekend!? :D:D

[Neighbors]

Not if it's in conjunction with the tech day, LOL! I'd have eighteen people wanting exhaust work done :D...

Now, if you wanna show up later that afternoon...

[Rusman]

Originally posted by Neighbors
Not if it's in conjunction with the tech day, LOL! I'd have eighteen people wanting exhaust work done :D...

Now, if you wanna show up later that afternoon...

But...but...!

I have the parts now! WOOOOOOOOOOO

Since my camera is a piece of shit, I can't post any pics of it, but let's imagine a stock 94/5 GT header in all it's restrictive glory. But there on one of the exhaust tubes is a beautiful, nicely welded fitting, ripe for the picking!

I test fit the EGR tube and it fit, of course.

/me is excited

[Neighbors]

Good deal! We have a winner!

[Rusman]

Mr Neighbors, will I need to bring the EGR tube with me whenever the header gets done? My plan is to return it to Tommie Vaughn and the sales guy told me not to keep it very long.

[Neighbors]

You might bring it with you Saturday Rusty, just in case...

[Rusman]

Originally posted by Neighbors
You might bring it with you Saturday Rusty, just in case...

Will do, but I understand that LL's come first! :)

[Rusman]

Interestingly, I received in the mail today an EGR bung from Mac Products! It fits the EGR tube piece perfectly, but themating point looks different than the stock piece. It does have about 4 inches of stock so it can be sized to fit, I guess.

It was very cool of Mac to send this part, at no charge even! I'll be bringing it along tomorrow.

[Rusman]

I dunno who all is following this thread anymore, besides myself and Chris :), but I'm giving my final update!

Tonight, Chris cut and welded the EGR fitting to my BBK, non-emissions equipped, header. The man is a true genius (despite what he says!). Watching him work with common tools, a coathanger, and a welder was amazing.

Besides that he makes some damn good deer chili! :D

I'm very glad that Mac found what I needed and sent it to me. Otherwise we would have been stuck, most likely. I'll get some pictures of it (the header, not the chili) pretty soon (tomorrow) and I'll post them for all to bask in the glow of genius ;).

Finally, congrats to Robert (LOL)!

[AGirlWithACoupe]

Kick ass, Rus! Glad you got that all worked out!