boxpin Posted April 20, 2012 Report Share Posted April 20, 2012 I live in California where the sun shines a whole bunch and the smog laws suck. I have a 95 with the EGR port that comes off the exhaust manifold.Could a port be welded onto the cast manifold? I have several donor exhaust manifolds to play with. Any other options out there? I have to have the EGR system to smog the car so removing it just is not an option. Please dont suggest it. Link to comment Share on other sites More sharing options...
B Mac Posted April 20, 2012 Report Share Posted April 20, 2012 Yes you can get a fitting welded to the manifold. If you have a 96-97 ecu, the car won't look for egr and won't throw a code. Still not an option? I'm sure Lucky could help with that. Link to comment Share on other sites More sharing options...
Mesoam Posted April 20, 2012 Report Share Posted April 20, 2012 Does CARB check based on model year? Do they really fish around to see if there's an EGR under the manifold because there is no way they could a visual on that IMO??? If so California is even more messed up than I had thought. The easiest thing to do is toss a 96-7 ECU in the car w/ the R mani, and plug the EGR port on the intake manifold. A blanking plate for the EGR takes all of 10 minutes to cut with a dremel Link to comment Share on other sites More sharing options...
boxpin Posted April 20, 2012 Author Report Share Posted April 20, 2012 The easiest thing to do is toss a 96-7 ECU in the car w/ the R mani, and plug the EGR port on the intake manifold. A blanking plate for the EGR takes all of 10 minutes to cut with a dremel You ignored the 'dont tell me to plug it'. They do visual inspections and also have been known to vacuum test the functionality of the EGR valve. Its not about how to make it work without it, it has to be there. Believe me it would have been gone a long time ago if it was possible. Link to comment Share on other sites More sharing options...
caanglin Posted April 20, 2012 Report Share Posted April 20, 2012 I don't see why you wouldn't be able to tap in to the R manifold. Even though you don't want to, maybe you could get a intake mani without EGR and bore it for your TB. Link to comment Share on other sites More sharing options...
D s50r Posted April 20, 2012 Report Share Posted April 20, 2012 Yea if u swap over a intake manifold without egr (i have one if u want)and an ecu from 96-97 no one would be the wiser... Or like others have said drill and tap a hole for the egr I'm sure a machine shop is very capable of doing that for youOh and does the egr have to be on the manifold? Can u extend the pipe and put it on ur downpipe? A lot easier to do it that way Link to comment Share on other sites More sharing options...
boxpin Posted April 20, 2012 Author Report Share Posted April 20, 2012 Guys, your missing the point here. I have to keep the EGR. When I went to the BAR last year they had schematics and drawings of the parts and locations. Its a 95 which means I pass under 95 rules meaning no OBDII testing and an EGR. That is good. Last year they actually looked at the turbo but I got away with it. I dont mind tapping into the R-manifold. Part of my question is if you can weld onto cast steel? I have never welded cast...can it be done. Right now I am thinking of cutting the port off a spare manifold and welding it onto an R manifold. I just need to know if it will stick. Link to comment Share on other sites More sharing options...
Dick Dastardly Posted April 21, 2012 Report Share Posted April 21, 2012 Guys, your missing the point here. I have to keep the EGR. When I went to the BAR last year they had schematics and drawings of the parts and locations. Its a 95 which means I pass under 95 rules meaning no OBDII testing and an EGR. That is good. Last year they actually looked at the turbo but I got away with it. I dont mind tapping into the R-manifold. Part of my question is if you can weld onto cast steel? I have never welded cast...can it be done. Right now I am thinking of cutting the port off a spare manifold and welding it onto an R manifold. I just need to know if it will stick. He isn't kidding. Why does everyone keep coming up with ways around it? In CA they look at schematics for every car based on year and check to make sure every component is in place, then they test to make sure it all works. Cheating the CEL doesn't mean dick there. Cast iron can be welded but it isn't easy to make it a good weld. Nickle rods and pre-heating are typically used..Generally welding cast is used to repair a crack in a part (both pieces to be joined are of the same alloy/composition). The egr port is probably not the same alloy as the manifold which will make it very hard to create a strong permanent weld. There are pros who may be able to do this reasonably well if you know some fabricators, ask around. Link to comment Share on other sites More sharing options...
boxpin Posted April 21, 2012 Author Report Share Posted April 21, 2012 Thanks, I was thinking of grinding a section out of the egr manifold then welding that to the R manifold. That way they would be the same material. Link to comment Share on other sites More sharing options...
DVolvoguy850T5 Posted April 21, 2012 Report Share Posted April 21, 2012 Here is a video of basic ARC welding on a cast iron mani. You can do it per the vid's instruction. The instructor used a 110 v ARC welder. I do know that drilling cast iron is a real PITA. I would use a drill press so you can lay the manifold flat on it's working table. I wonder if it would have a tendency to warp during welding? However I am not sure if the mtl the original POS turbo exhaust mani is made of. I just bought an 06 R mani and it looks different? Maybe age? You may be able to find a totaled R in a pick a part yard there in Cali. It should have an EGR port already in it? (not sure though) Or you can build a rocket out of an 81-83 242 turbo? hehehe... On that note, IL is known as the most corrupt state in the union? I beg to differ and thank the good Lord that I no longer live in California. Link to comment Share on other sites More sharing options...
burnout8488 Posted April 21, 2012 Report Share Posted April 21, 2012 I don't think R's (even CA versions) used EGR, so there wouldn't be a provision for that on the manifold. Link to comment Share on other sites More sharing options...
Mesoam Posted April 21, 2012 Report Share Posted April 21, 2012 He isn't kidding. Why does everyone keep coming up with ways around it? In CA they look at schematics for every car based on year and check to make sure every component is in place, then they test to make sure it all works. Cheating the CEL doesn't mean dick there. I see....Helps explain CA's budget deficit... Link to comment Share on other sites More sharing options...
Dick Dastardly Posted April 21, 2012 Report Share Posted April 21, 2012 Thanks, I was thinking of grinding a section out of the egr manifold then welding that to the R manifold. That way they would be the same material. They probably aren't the same alloy. It would appear to work but then the weld itself would not penetrate and the EGR boss would leak and the weld would eventually crack. (like a cold solder joint that looks okay, but doesn't stick.) That video shows what I said in my previous post, crack repair, not the same as welding 2 separate pieces of dissimilar cast together Link to comment Share on other sites More sharing options...
goldponcho Posted April 21, 2012 Report Share Posted April 21, 2012 What is California's rule on engine swaps? I haven't really looked into it for myself, but my understanding is if the engine is from a newer-model year vehicle, and all emission-equipment (for the model-year) are in place, it's legal. I understand you've stated several times you need to keep the EGR, but have you ruled that possiblity out? Could you get by with the '96-'97 ECU as part of a "newer" engine? Link to comment Share on other sites More sharing options...
burnout8488 Posted April 21, 2012 Report Share Posted April 21, 2012 I remember reading a lot of information about CA swaps back in my honda days, and what you said sounds about right. It probably explains how they can legally drive a 1996 Civic with a K-Series Accord engine swapped in, as long as the intake and all of that are still CARB legal. Link to comment Share on other sites More sharing options...
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