Oh well - it was worth a try - it came apart on him today.

I'd advise you to keep the copper pipe in yours and use the QuikSteel to seal up the leaks. That should last a little longer - I'd also advise a Tiger Patch wrap over it for extra security.

 

Working on them isn't really fun. Creating your own is, specially if it works lol. I have to work on a Saturn next week. Have to make it road-able from here to Calif. .. What pressure, - at least I have 10 days to do so once I get it .

 

Sorry it didn't hold up, that noise is so annoying. Yeah, like jbrew said, repeated expansion and contraction in that area is an issue.
Just got back in from trying a few things with mine, no luck. I got to thinking, the copper tube is restricting the flow slightly, wonder if that small amount matters? It's 1/8" smaller inside with the copper.
I'm just debating whether to just change the manifold while I'm waiting for the other parts to come in, can't drive it right now anyway. You can get those China made manifolds for $30-50, but don't know how good they are. The Dorman is China made, they all appear to be the same manufacturer.

 

The pipes alright as long as it ends an inch or so before the orifice. The DPFE won't sample(meter)right, - if that copper is butted against.

How it works (meters), System info, -

http://www.fordscorpio.co.uk/egrmonitor.htm
__________________________________________________ ___

Pipe Orifice Diag, - scroll to the bottom, -

http://www.fordscorpio.co.uk/egrsensors.htm

 

Great, thanks! It needs the extra support of the smaller pipe inside, then I expect the Quiksteel will do the job.
Thanks again jbrew, much appreciated!

 

Here's something I found on another site: Walker cat converter air tube repair kit 35574, someone used one to patch one of these egr tubes. Wonder if the rubber in this kit will hold up in this application?

 

It's too hot for any kind of rubber.

 

You're probably right.
I ordered a manifold.
Hope the fasteners come loose without a lot of trouble. Or breakage, lol.

 

By the way, I abandoned the Quiksteel and copper pipe idea because I envisioned particles of Quiksteel breaking off and flowing through my egr to the intake valves.
Just didn't think it was the best idea. If the nuts come off the studs, manifold replacement is easy and really the better way to go.