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About 2" longer than the stock lower intake manifold runners. He cut the flange off that normally fits to the stock upper and welded/blended the extensions between the plenum and runners. He did do the EGR tube. The problem with running it inside or under is the way the stock EGR valve to...

That is correct...the EGR will result in cooler cylinder combustion temps. And as Poodles pointed out, the stock port can get clogged over time...on this FFIM, it's a piece of cake to clean the tube. Seth does a nice job...this one is a heavily customized mid-length runner with provision for...

I remember that one ;)

You used a rotary abrasive to clean the block deck? :eek3:

You could, but it would be quite a bit of work. When I had this done, talked with Seth a lot about that exact issue...inside or outside. Plus the way the EGR fitting angles up would make it very difficult. On the stock EGR, the manifold port (part of the casting) leads to an opening right...

Just measured a NA filter stud...its M20x1.5 on the block side.

LOL...True! When you do though, it just makes you want a 600 HP car ;)

The problem with the EGR port is it needs to be close to the TB. Otherwise exhaust gases will not mix uniformly with the intake charge. It needs to look something like this:

I understand. But, to say "its not about warpage, its about smoothness" is incorrect. Regardless of the odds, the block should be checked for warpage and that's for any HG...a warped deck will just about assure it's not going to seal. Also...like I've said a couple times now (in different...

http://www.supramania.com/forums/showpost.php?p=977478&postcount=22

The TSRM (Pg EM-74, Step 3) says max warpage for the block deck is .05m or .002". Then it says if it exceeds the above, replace the block. I wonder why the TSRM would say that ;) Maybe it's because a warped block won't allow a HG to seal? That's exactly why...a flat block deck is even...

If you get the OEM bolts, torque them down to 72 ft/lbs vs the value in the TSRM ;)

Ok...gonna say this ONE more time: Pressure test your coolant system. Grab a block tester at NAPA to see if there is exhaust gas in your coolant...if it is, you got another BHG.

Ummmm...0.20 is twenty hundredths -or- two tenths. ;)

Did you purchase a filter stud for the 7M-GE motor to attach the sandwich plate? Are you deleting the stock filter head and going with a full flow remote filter and cooler circuit? As far as I know, the studs are the same...3/4"-16 on the filter side.

But it's a pretty paperweight...real conversation starter ;)

Ok...that's likely not it. Check your IC hoses for cracks...especially the ones coming off the turbo to the IC. The coupler from the 3000 pipe to the TB likes to crack too.

What make/part # plugs and at what gap? What make plug wires?

Maybe he should stick with what's working ;)