Plugging an egr hole in a cast manifold?

I want to plug a round EGR hole exactly like the one in the cast iron manifold below:

(It is the thing sticking off of the right side)

Any suggestions?

Bolt? Spark plug?

bolt + red loctite?

It may be easier to turn the removed EGR valve or pipe into a plug?

Too small of an orifice to just sruff a kitten into...

Being cast, I would just tap it out, and install a bolt with a copper washer.

Much easier to revert to stock if you need to later.

Hocrest wrote: It may be easier to turn the removed EGR valve or pipe into a plug?

Don't have it. Had it many years ago, don't anymore. Not a common junkyard car.

Take the manifold to your friendly hardware or farm supply store and try to find an NPT pipe plug to fit. If nothing fits, drill and tap for the next larger pipe size and plug with red loctite.

Rog

emodspitfire wrote: Take the manifold to your friendly hardware or farm supply store and try to find an NPT pipe plug to fit. If nothing fits, drill and tap for the next larger pipe size and plug with red loctite. Rog

The manifold needs to stay on the car but the consensus is pretty clear so far: tap the hole and thread something in.

There is no reason to use red loctite. I don't know why anybody would recommend that. If you need to put something on it, use some teflon tape or pipe dope.

If I had to put something on the threads I would use that muffler mender past that comes in a tube.

You could try brazing a plug into it.

The way to defeat loctite is heat. For example, I retained some 45mm ID bearings on a bike-engine car diff w/ Loctite retaining compound. As an experiment I thought I'd see if they'd budge in my 20 ton press, and I backed off when I became concerned I'd deform the diff case.

Then I grabbed the bearing in the vise w/ the diff hanging down w/ a folded up movers blanket on the floor and started heating w/ a MAPP torch. In about a minute I gave the diff a little tap and it fell right out of the bearing.

So red Loctite on an exhaust manifold will do 'nothin.

If it's straight threads, bolt + copper washer. It may vibrate out, so possibly bolt, copper washer and safety wire. If it's pipe threads - cast iron or steel plug from the hardware or plumbing supply store. Teflon tape makes it seal better.

Drive in a freeze plug and tack weld it to keep it from falling out...

measure hole, go to napa and find freeze plug of appropriate diameter. knock it in place, go drink beer. i removed the AIR system from my '69 corvair and plugged the holes this way.

[Ghetto] I was afraid i would break the manifold getting the check valve for the AIR system off my Yugo(to replace it with a pipe plug), so I just hose clamped many layers of aluminum foil over the check valve. I suppose hammering on a copper pipe cap might work better. [/Ghetto]

Hang a wastegate off of it...