Added a 1 1/4 inch steel bung to a cast iron elbow

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Doing some emissions upgrades to an engine and the plumbing they sent did not support our fuel cooler so time for some modifications.Last edited by 76GMC1500; 11-16-2012 at 12:20 AM.
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Reply:Nice modification. Did you grind down the inside or just leave the bung excess hanging out? Not that it really matters either way. Just curious.Is this an MUI to EUI conversion? Is the large bung for the egr outlet?
Reply:Left the excess bung hanging, it only protruded 1/4 inch.  This is an EUI engine, 1998 build.  The conversion involves turbos, cams, a larger 2-pass aftercooler, and an ECU upgrade.   The elbow is the aftercooler pump suction elbow.  The original engine had a single pass aftercooler with the outlet at the rear of the engine.  The new aftercooler is two pass so the outlet is on the same side as the inlet at the front.  Our fuel cooler piggybacked off the aftercooler circuit as it is supposed to run below 120F and our fuel needs to stay below 130F.  1 1/4 matches the fuel cooler plumbing but there will be an throttle valve or orifice plate to keep the cooler from robbing more water than necessary from the aftercooler.  The fuel cooler is mounted in the return from the engine to keep the engines from overheating the day tank.