Will do . I just got to make some extra cash this week so I can get this all done. The studs are for sure. I found a set pretty cheap. I can`t believe it. The good lord is looking out for me. I got to thank you all for the help . I will plug that cooler up then , welding the caps in place is the best bet I would think?

 

Yes. Again, if you're just welding freeze plugs, from what I've been told the end by the hot side needs to be completely filled with weld. I've heard of cases where guys melted the freeze plugs. They're thin material. Heat + boost pressure = pop.

 

So I could use some stainless in there, maybe tig weld them all the way around? I can`t believe one company sells this welded up for 399.00 that is just insane. I think it is because they want you to buy there upgraded cooler.

 

Yeah find a local waterjet guy or something even, have him cut out some simple circles out of some scrap material and tig them in. Or just by a couple small sheets of material from mcmaster or somewhere local.

 

I cheated, I actually cut up my EGR cooler, the side by the intake is only about 3" long and the side by the ex. is only about an inch long, and I used metal the the cooler itself to totally cap off the ex. side piece even though I put the freeze plug in it.
The main reason I did it this way is now when I have to remove intake I don't have to bother with unclamping the cooler the exhaust, plus I don't have to worry about the cooler getting plugged up, and man it was nasty inside of the cooler, alot of grit in there. If I can figure out how to do the photobucket thing I will post some pics.

 

Well I had a decent day today so I just might be able to swing those ARP Head studs. I have to still find a good welder to help me plug the EGR cooler up. My EGR cooler looked pretty good to me which is weird because all the ones I have seen off the trucks looked pretty bad at the dealership. I kinda drive it fast a lot though.

 

Be sure to replace that rubber hose and BS clamps with a stub of heater hose and REAL hose clamps when you re-install your welded up cooler. The mystery coolant leak in my 03 was a result of those lame "hose clamps" on the EGR cooler.

 

Thank you the last thing I WANT is a coolant leak.

 

There are some pics of my modded cooler/delete in my album, not sure how to link it here though.

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Just click on the camera by the join date.

 

I saw them just a bit ago pretty cool how you did that. I wish I was that good at fabrication. Very nice job. But you gave me ideas.

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I am confuse are you talking about the stock clamps and hose? Do not use them? Is that what your saying?