i am having trouble with my homemade egr block offs leaking. can i just use the old sensor and plug the hole with RTV/ a boot? i got some rtv in the egr suction will this hurt my intake / engine at all?

 

What "sensor"? There's no sensor in the EGR system. Do you mean the EGR valve itself?

 

yup

 

What i did was i took my old EGR valve and cut the top of it off and ground the little metal plunger off too. I basically stripped it down to just the cast metal mounting block. I then took a piece of house flashing and traced out the pattern and cut it out. Then i used some RTV around the flashing and slipped it on, then put the EGR mounting block on to hold the flashing then tightened it down. It hasn't leaked on me yet.

 

holy **** you just confused the **** outta me

but i will try that

 

Did you use a gasket when you installed your plate? Is the plate thick enough to avoid deforming when you tighten down the nuts?

I have the aluminum plate from SJM Manufacturing, a stock gasket and some RTV and there is no leakage.

 

Here is a pic of an EGR valve i found. Its similar to the one on our cars but not exactly the same.
http://www.mustangmods.com/data/1787/egr_valve.jpg
I took my old EGR valve off and i broke/cut the top of it off, the part with the green arrow pointing to it. I then took the cast base part(it has the red arrow pointing to it) then traced the shape of it out on a piece of thin sheet metal. You basically make a gasket out of metal but don't put the center hole in it. Then i used some RTV on the sheetmetal and put it on the intake and then i used the cast base part to help sandwich it in place. It has worked fine for me.

 

o i get it great idea, i will try that. i hve some copper lying around think that will work?

 

It should. You just need something to block off the port.

 

I'll send you a plate or set of plates if you need them. PM me

 

what about getting RTV into the intake? wil it be very very bad? is it worth pulling the intake again to clean out?