I'll look into tapping it and then machining/grinding the bolt to contour nicely into the plenum. It's not just a simple hole, it's a 3/4in vertical notch I put in there; opps. I already have to make a plate that blocks off the EGR from the floor and what is left of the old TB opening. Probably going to take the mill to it again and make a slight recesses pocket for a piece of aluminum sheet that I'll bend up and then screw in place with lots of tiny self tapping screws and a back coat of JB weld or some other epoxy to make sure it all seals. I might try HRM's aluminum casting idea to back fill the EGR passage and the back side of the TB hole, but the plate will be doing the hard work.
I forgot to mention that the base of the new plenum will not be welded in place, it'll be held on by 4 bolt into the old injector rail bolt bosses and sealed with Aviation Form-A-Gasket. I'm still thinking about how to design it and if it should put some flow vanes in the base. Something like:
[IIIIIIIIII]
across the base to help straighten and equilize the air into the lower plenum. I also need to deal with the funky little bumps in front of each of the port openings into the plenum. I think I'm going to epoxy them up and grind into a bell mouth shape to smooth up the entrances.
I forgot to mention that the base of the new plenum will not be welded in place, it'll be held on by 4 bolt into the old injector rail bolt bosses and sealed with Aviation Form-A-Gasket. I'm still thinking about how to design it and if it should put some flow vanes in the base. Something like:
[IIIIIIIIII]
across the base to help straighten and equilize the air into the lower plenum. I also need to deal with the funky little bumps in front of each of the port openings into the plenum. I think I'm going to epoxy them up and grind into a bell mouth shape to smooth up the entrances.
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