lightning egr spacer?

[HATNINJA]

hey guys i am not interested in this for myself because i like pimpin not racing. but i am starting c.a.m. (computer aided manufacturing)class this semister and also have unrestricted access to the colleges machine shop due to being a assistant. ive seen in posts something about this allusive lightning egr spacer. if its that hard to find maybe i could fab some. i wont do it for free though because my time during the semister is valuable to me i study my ass off to keep up a good grade avg. from what i can tell the only thing costwise for us would be the aluminum. maybe someone can post a sketch so i can start working it out on cad now then when the semester starts ill see what i can do. also how much different is it than the spacer for the lopo 5.0.? is the only difference the center bore?

[zoomie]

hey guys i am not interested in this for myself because i like pimpin not racing. but i am starting c.a.m. (computer aided manufacturing)class this semister and also have unrestricted access to the colleges machine shop due to being a assistant. ive seen in posts something about this allusive lightning egr spacer. if its that hard to find maybe i could fab some. i wont do it for free though because my time during the semister is valuable to me i study my ass off to keep up a good grade avg. from what i can tell the only thing costwise for us would be the aluminum. maybe someone can post a sketch so i can start working it out on cad now then when the semester starts ill see what i can do. also how much different is it than the spacer for the lopo 5.0.? is the only difference the center bore?
how about just design one based from the lopo spacer but 65mm?

[HATNINJA]

ok so thats the only difference? if that is the only difference i may be able to machine existing spacers. i will have to do some analysis to see if the thinner wall of the bore can take the heat from the egr. is there anyone who can tell me the hottest these spacers get? the only spacer i have is on my car but i would also need to know the original id and od of the bore.
i read on here that ford no longer makes the tv bushing replacment i was also thinking of making a butload of brass tv bushings and selling them with the clips for maybe 15 bucks apiece if anyone would be interested.

[zoomie]

ok so thats the only difference? if that is the only difference i may be able to machine existing spacers. i will have to do some analysis to see if the thinner wall of the bore can take the heat from the egr. is there anyone who can tell me the hottest these spacers get? the only spacer i have is on my car but i would also need to know the original id and od of the bore.
i read on here that ford no longer makes the tv bushing replacment i was also thinking of making a butload of brass tv bushings and selling them with the clips for maybe 15 bucks apiece if anyone would be interested.

original bore is 55mm i would suggest running to the junkyard and getting one they are usually 10 bucks, the stock lopo spacer can only be bored out to 63mm safely, autozone carries a grommet pack for 5 buck ,that suits me fine replace every 5 yrs im good.

[88grandmarq]

there are actually 2 issues, the inlet size and the 2 studs cast into the housing for the throttle linkage bracket.

the stock EGR spacer can safely be bored to 63mm, which works fine for the stock HO upper intake, which has a 63mm opening. however the GT40 style intakes (GT40,Cobra and Explorer) use a 67mm inlet.
The stock EGR spacer will NOT seal when bolted up to a GT40 style intake.

the stock EGR spacer also has 2 studs to mount the throttle cable bracket. The Fox body/Mustang EGR spacer does not have any provision for these studs, so you can not mount the throttle linkage bracket.

the Lightning EGR spacer fits the bill on both accounts, it has the proper inlet size and it has the 2 studs to mount the throttle linkage bracket.

[merc91]

I just whipped one off in 2 hours at the collage last week...bored out an HO spacer to 67mm on the lath, then drilled and tapped and sealed in studs for the throttle plate. I think i'm going to do 5 or so next month and anyone who needs a spacer and doesn't want to pay tons for a super rare lightening, let me know. Or i'll bore it to whatever you like same goes for 63mm LOPO spacer.

[gadget73]

Modding the Mustang stuff is probably the easiest and cheapest route. There are shittons of them available for a song.

You could mill out a copy of the Lightning unit from billet aluminum, but thats a lot of machine work. It could easily be made into something superior to the original Ford unit though. You'd be ahead of the game to make a cast of the Lightning part, then produce a set of molds from that. The original Ford stuff is raw cast with just the gasket surfaces milled flat. Still, lots of work to duplicate the Lightning stuff no matter how you do it, machine vs mold.

[88grandmarq]

btw... just scored 2 lightning EGR spacers off nloc.net

woot !!

[HATNINJA]

so gadget, are you saying that machining from raw aluminum would be a waste of my time or not? I will do as many of these spacers that I can in a semester if it is worth my time. But if I can't make some money off it, I won't bother.

if it's not worth my time gadget, tell me, but I can make a quality product if you guys want along with tv bushings. Just give me a hollah, i don't wanna chase my tail.

[HATNINJA]

merc 91 shame on you...get your own thread buddy...hee hee

[1980c10]

All you would really have to do is machine a blank block the shape of the panther egr, with the studs in the correct locations. Then when ever you go an order machine out the center bore to the correct size. Or you could just make up several with a 70mm opening and sell them that way. I am talking about egr delete plates btw not a functional egr spacer.

[HATNINJA]

ok, just tell me how much money you would pay for one. and how much money you would pay for a bronze tv bushing set because i love you guys like my sister but even i don't work for her for free.

[BGoins12]

btw... just scored 2 lightning EGR spacers off nloc.net

woot !!

HOW?!?!??!?! I just posted on there and have had no luck!

[HATNINJA]

no shit guys. you wanna get tongue jacked by everyone else fine. I'll make these for ya, but I won't make 'em for free, so talk to me.

[HATNINJA]

you know what ass jack...don't waste my fuckin time with what you got or what you're gonna do, i made you guys sn offer, talk to me. i don't wanna hear what you got or what you can do if you could do all this i wouldnt be sayin all this shit right now. so seriously i could make these for ya if you want em. simple as you pm me and boom its there. i just don't know how much to charge for them. tell me what they are worth.

[88grandmarq]

you know what ass jack...don't waste my fuckin time with what you got or what you're gonna do, i made you guys sn offer, talk to me. i don't wanna hear what you got or what you can do if you could do all this i wouldnt be sayin all this shit right now. so seriously i could make these for ya if you want em. simple as you pm me and boom its there. i just don't know how much to charge for them. tell me what they are worth.

whoa... chil-lax, dude.

[1980c10]

Yea, relax. Anyway I think I paid $25-$30 for the egr delete for a mustang which is what I used on my car. But that was from a mass production place. So maybe $40 for your peice if it's good quality and everything fits correctly.

[merc91]

ya learn from experiance...other's as well as your own. People on here tell thier personal experiance and others learn from it. What the concensus is pretty much most people can get ahold of a spacer to do the job for $50 or less by using different metheds than machining one from a block of aluminum. It's so easy to make a mustang spacer work it wouldn't be worth your trouble an money to make on from scratch, i paid $5 in the end for my spacer, so I wouldn't pay $6 myself.

I've learned a ton from the guys on this forum and for everything they have done for me knowledge wise, machining up 67mm spacers from stangs and shooting a few out for $40 to thier door would be my way of making myself somewhat usefull for once haha.

So as far as getting ballpark $150 i'm assuming that would make it worth your time, probly not going to happen but who knows, at least your throwing it out thier as an option, someone might take you up.

[gadget73]

so gadget, are you saying that machining from raw aluminum would be a waste of my time or not? I will do as many of these spacers that I can in a semester if it is worth my time. But if I can't make some money off it, I won't bother.

if it's not worth my time gadget, tell me, but I can make a quality product if you guys want along with tv bushings. Just give me a hollah, i don't wanna chase my tail.

if you want to make functional egr spacers with operable egr ports, I suspect the machining would take way too much time. I actually have my suspicions that its impossible to do since the original casting relies on internal passages that you simply cannot make with a mill or lathe from a block of solid aluminum. it would need to be cast into the piece. If you want to experiment with metal casting, this might be a cool project to start with though. I think you'd need to do sacrificial castings to get those internal passages done, then just finish it on a mill for proper mating surfaces. Time consuming to get the initial casting correct, but once you have the master mold, you're golden.

Blockoff plates that just provide a place for the throttle bracket would be vastly simpler and certainly doable without having to get too fancy. The bigger question is how much time would it take you, and how much could you sell it for? I cant answer about being worth it. Something else to consider might be modding the Mustang spacers for folks. That would give you an operable EGR valve that will mount the throttle body properly.

[HATNINJA]

you know what ass jack...don't waste my fuckin time with what you got or what you're gonna do, i made you guys sn offer, talk to me. i don't wanna hear what you got or what you can do if you could do all this i wouldnt be sayin all this shit right now. so seriously i could make these for ya if you want em. simple as you pm me and boom its there. i just don't know how much to charge for them. tell me what they are worth.

sorry guys the jim beam was getting a hold on me at this point. i apologize for this rude comment. gadget you are on the right track, i did have a class on casting with sand molds i think i may try something like that if i can get a hold of a lightning spacer. once again im sorry for snapping like that.