Here are some pics of the process, not complete, but a couple of hopefully helpful shots. The instructions are very good, follow them.

Coming out of the engine:



Had to knock this part loose with my brass hammer:



Copper disc and the egr in the vice as an anvil:



Heat going toward the disc:



The blueish color you want, about 25 seconds of on and off heat application (watch the heat, not the clock):



Using the egr as the mandrel to form the disc (Shot taken before heat treating):




And after forming. Note that it's shining back up with hammering:



Installed, be sure to let the sealant cure for a day:

__________________
1985 300D-189k The 'UD', Ivory and Pinkamino
1979 300D-211k Dark Gray, Parchment
A 1980 Harley-~166k and
A 1994 Ford diesel pickup-349k and
A 1990 gasser Volvo wagon-145k

sorry if I missed it, but what sealant did you use?

Thank you! you are my hero, I was loooking for a thread which address this MOD, nicely done.

Most likely, the one that came with the kit.

__________________
1984 300TD Turbodiesel - 272k
- Daily Duty
1985 300D Turbodiesel - 315k
- "Recommended for competition events only"

It was tube that came with the kit. High temp copper, Permatex I think.

__________________
1985 300D-189k The 'UD', Ivory and Pinkamino
1979 300D-211k Dark Gray, Parchment
A 1980 Harley-~166k and
A 1994 Ford diesel pickup-349k and
A 1990 gasser Volvo wagon-145k

Can you elaborate on where to get the 'kit'? Sorry, maybe I'm coming late to the party, great procedure just would like to understand more about where to get what.

Ask Brian Carlton who is on this forum...

__________________
1987 300SDL 314K mi, counting; #22 Head
1999 E300Turbo 405K original miles
1997 E320 180K mi (Son's)
2002 ML320 (Son's)
1998 S320 140K mi (Son's) sold
1985 300SD 311K mi
1984 300D 324K mi (killed by a hit-n-run turd)
*************************************

Nice work.

Having a vice sure makes that job a pleasure.

Yes it does, and thank you for the kit!

__________________
1985 300D-189k The 'UD', Ivory and Pinkamino
1979 300D-211k Dark Gray, Parchment
A 1980 Harley-~166k and
A 1994 Ford diesel pickup-349k and
A 1990 gasser Volvo wagon-145k