Originally Posted by judgemikdredd
nice! can u take some closer pics of the egr port so i can see how u did that
I drilled a hole in, tapped it to 3/8" pipe thread, added a nipple, cut the end off the original stove pipe, flared it and put a 5/8" flare fitting onto it. Sealed all the pipe thread with high temp thread sealant.
The blue gasket sealant is temporary because I didn't have the correct TB gasket, and I want to drive it over to my dad'* house so I can weld the new rocker panels on this weekend.
For the vacuum port, I cut the mounting flange off for the old vacuum port and welded a new piece of aluminum in it'* place. Tapped that out 3/8" and added a tree. Tree is a nipple with some holes drilled into so I could braze some barbs onto it, then added an elbow up top for a barb for the brake booster.
Also note if anyone is intending to do this, you cannot reuse the plastic manifold'* bolts, they are too long aside from the one that is on the back right next to the TB which is too short. You will also have to shorten the tabs on the fuel rail because the mounting points are higher on the aluminum manifold. The old TB shield doesnt line up properly as you see, I will probably fix that later. The TB normally sits about 2-3 inches further to the drivers side, but the aluminum manifold is not as wide as the plastic one.
Like I said before..... It isn't worth bothering to do this. You can spend a few bucks more, get a brand new plastic manifold, and have no worries for longer than most people will own their car.