no more EGR *pics*

[Identity Crisis]

Thanks for the info guys.

[TurboSedan]

just an update. i did pull the allen head set screws back out and used JB Weld like Pat suggested. i'm definately more confident about doing it this way

also, i didn't end up buying a McMaster-Carr manifold distribution block like i used on my Lebaron GTS. this was because the inlet source isn't in the center of the block, which would cause mounting problems on my Cutlass due to the limited space in that area. it would work, but in order to mount it i'd have to either use a double sided block with an odd # of ports on each side (to keep the block centered with the EGR hole - and that would defeat the purpose of using a double sided block since the EGR flange would be right there behind it leaving me with not enough outlet ports to use) OR i'd have to mount the block sticking straight out perpendicular to the EGR flange which would be really ugly. sooo....i bought this one from TurbosUnleashed instead:

http://turbosunleashed.com/shop/product_info.php?cPath=136&products_id=269

it's also smaller (3/4" x 3/4" square) than the McMaster-Carr block (1" x 1" square). this will offer even more clearance between the throttle arm & the distribution block. as you can see it has a 1/4" NPT source in the center of the block and it's short (2 & 5/8" long) so i can mount it parallel to the neck of the plenum and it will look much nicer. unfortunately the block is only available in blue but i don't mind too much since my car is blue anyway. i really wanted the same block with 3 ports on the side instead but TurbosUnleashed didn't have them available and it might have been too long to mount there anyway. oh well.

it should arrive here next Monday or Tuesday and i'll be installing it right away so pics will be coming soon. in order to mount the block i went to NAPA and spent $19 on NPT fittings:

to actually mount the block:

- 1/2" male NPT-to-1/4" female NPT bushing. this will thread directly into the plenum where the brass plug is now.

- 1/4" male NPT-to-1/4" male NPT adapter to connect the distribution block to the adapter bushing listed above ^

as far as ports go:

the two ports on the end:

- 1/4" male NPT-to-1/8" female NPT bushing. threaded into that i have a 90* 1/8" male NPT-to-1/4" hose barb fitting. this will be on the end opposite of the TB and pointed downwards to source the FPR (vacuum line will be short and run under the TB/plenum neck area.

- the other side of the block will be the same - a 1/4" male NPT-to-1/8" female NPT bushing with a 90* 1/8" male NPT-to-1/4" hose barb fitting. the fitting will point towards the firewall and source the HVAC/cruise control.

as for the two ports on the side:

- straight 1/4" male NPT-to-1/4" hose barb fitting. this will be on the side further from the TB and will source the MAP sensor.

- the port next to that will have a 1/4" male NPT compression fitting (nut & ferell) to run the nylon line to to source my boost/vacuum gauge. this will be on the side closer to the TB of course.

kind of hard to explain but hopefully i can show installation pics early next week.

later

EDIT for shameless plug:

http://60degreev6.com/showthread.php?t=34876

[TurboSedan]

got it all installed today. the nipples for the FRP & MAP sensor will stay capped & zip-tied until i have time to remove the plenum and take out the stock vacuum lines. as you can see from the last pic, the 3/16" vacuum line for the FPR will go under the plenum neck (probaby be about 10" long). as for the HVAC/cruise control vacuum source, i plan on just running it over towards the vacuum block and attatching it there so i'll have NO vacuum lines under the plenum.

http://www.turbosedan.com/cutlass/engine/DSC03003.jpg

http://www.turbosedan.com/cutlass/engine/DSC03004.jpg

http://www.turbosedan.com/cutlass/engine/DSC03005.jpg

EDIT: complete underhood pics here:

http://60degreev6.com/showthread.php?t=34939