I ended up going down the drill and tap the manifold route.
The spacer pipe was ali, and it was proving difficult finding fittings for it in ali to weld to it.
So I removed the spacer, then got an old microfibre cloth (which I figured would have any shards of ali stick to it) I then put that down in the manifold to catch any bits from the drilling. While I was drilling I had the shop vac running to suck up everything. Drilled very slowly and then did the last bit by hand.
When it came time to tap the hole, I smeared grease all over the end of the tap to trap and metal.
Despite general nervousness about dropping something down the intake, it all went ok. It hasn’t blown up on me yet anyway…
Boost gauge is working. Although I need to drop past the parts shop and buy a couple of spring clips. The hose wall thickness is a bit much for the clips I had. T he hose colour was not my first choice, but it was all they had. I think I might replace the other vac hoses with this too as the other stuff is quite hard now.
Also my intake was surprisingly clean. Previous owner told me the EGR blanking plate was done at about 100K. I added the provent at 185k. There was some black oily residue in there, but only minor and no coking or anything caked on. I was concerned I was going to see a lot worse.
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