How hard would it be to add an EGR tube port to a non EGR head? I would want it to be done right, I cannot stand even minor exhaust leaks near the engine. I do have access to a bridgeport mill. Any advice? I'm currently looking for the proper head (phase 1 EJ22 with dual exhaust ports and EGR port), this would be my fall back plan.

its easy.... the hole is already cast into the head. just needs opened up and tapped. I have all the specs at my shop if you want them. If you do a search you might find them too( ive posted them up a couple times)

I have a spare head laying around the shop. Not sure which side it is, but it came from a 92 fwd 5spd wagon. You are welcome to it if it has the right port, or if you want to practice machining on this one first.

imprezas are a good place to look for the dual port 2.2 heads. I think they made them with dual ports for a bit longer than the legacys

its easy.... the hole is already cast into the head. just needs opened up and tapped. I have all the specs at my shop if you want them. If you do a search you might find them too( ive posted them up a couple times)

 

Yeah, send them my way. If anything I could send the head to work with my dad, he's a machinist with 47 years experience so I bet he could handle it.

yeah those EGR ports really are simple, they're just tapped into the exhaust stream. they're not really all that precise and the metal tubing that threads into it has plenty of flex. it just needs to see the exhaust stream. i'd just do it at home with a drill and be done with it, it's aluminum and there's nothing remotely complicated about it.

But it has to seal properly. I'm not worried about the drilling and tapping, but how do I ensure that I create the correct sealing surface for the EGR tube?