The method you choose to mount your Exhaust Gas Temperature (EGT) probe or other thermocouple sensor can have a big impact on installation ease, durability, and serviceability. Here’s a breakdown of the three most common methods:
1. Drill & Tap
How it works:
A threaded hole is drilled and tapped directly into the exhaust manifold, header, or pipe. The probe’s compression fitting threads directly into this tapped hole.
Advantages:
- Simple and low-cost installation
- No additional hardware required
Considerations:
- Requires precise drilling and tapping to avoid leaks
- Threads can wear out over time if the fitting is removed and replaced frequently.
2. Weld Bung + Compression Fitting
How it works:
A bung (a small threaded collar) is welded to the exhaust pipe or manifold. The compression fitting threads into the bung, securing the probe in place.
Advantages:
- Strong, durable mounting method
- Threads remain intact since the bung can be replaced if damaged
- Provides a clean, professional installation
- Better long-term option in high-vibration or racing environments
Considerations:
- Requires welding skills or professional installation
- Slightly more costly and time-intensive than drill & tap
3. Direct Weld Compression Fitting
How it works:
The compression fitting itself is welded directly into the exhaust system (no bung required). The probe is then inserted and secured.
Advantages:
- Extremely rugged and permanent installation
- Fewer potential leak points compared to threaded methods
Considerations:
- Not easily removed or adjusted once welded in place
- Requires welding equipment and expertise
- Best for permanent sensor installations where serviceability is not a concern
How to Choose the Right Mounting Method
- Choose Drill & Tap if you want a simple, cost-effective installation or would like the option to completely remove the sensor later.
- Choose Weld Bung + Compression Fitting if you want a durable, professional, and serviceable option—ideal for motorsports, performance, and long-term use.
- Choose Direct Weld Compression Fitting if you need the strongest, most permanent mounting solution and don’t plan on moving or replacing the sensor often.
Still not sure which option fits your setup?
Contact our technical support team for expert guidance on sensor installation methods tailored to your application.