Swirl flap blanks, what dimensions to make them?

[graham16v]

Any one know what the dimensions are for the swirl flap blanking plugs? ive just bought a manifold and want to clean it out and blank it all off. Would be nice if I could make the blanks up so they are ready for when the manifold gets here.

Thanks

Graham

[Dog_Book]

Just get it welded up, its easier to weld without the blanks in place

[graham16v]

I was planning on plugging then welding in the plugs.

[nutron]

I made up plugs and had them welded in, less chance of distortion then but I can't give you dimensions unfortunately. If you make them about 20mm, you should be able to take up any gap or quickly reduce down an aluminium plug from there.

[blackrusty]

What material is the inlet manifold made of?
Can you just weld it with a regular MIG welder?

[Hoody86]

For the cost of the material just buy them from flebay lol they ain't expensive

[Hoody86]

Also no you cannot mig a cast part will need to be tig

[Dog_Book]

What material is the inlet manifold made of?
Can you just weld it with a regular MIG welder?

It’s an aluminium alloy, tig then and don’t bother with blanks just weld up its easier for the welder that way

[blackrusty]

This is how I finally decided to solve this. Bought a 3/4 UNC thread tap. Threaded the manifold. Threaded a piece of steel which I then used to thread a 20mm diameter plastic rod.
Screwed the plug in with a pipe wrench and then cut off the excess. Repeat. Looks rough, but that's good enough for me.
Overall cost 10€ for the tap.
Also unplugged the EGR and everything works fine.
Hardest part for me was unscrewing the oil separator nuts/bolts.

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This is what the manifold looked like before cleaning.
340 000 km on the clock

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