1/4″ Stainless Steel Weld-on Kit

Permanent EGT Sensor Mounting Solution: 1/4″ Stainless Steel Weld-on Kit

Fabricating a reliable mounting point for sensors in a custom exhaust system requires hardware that matches the durability of the tubing itself. The 1/4″ Stainless Steel Weld-on Kit is the professional solution for installing 1/4″ (6.35mm) Exhaust Gas Temperature (EGT) thermocouples into stainless steel headers, downpipes, or manifolds. This kit eliminates the need for tapping thin-wall exhaust tubing, providing a robust, thick-walled boss that ensures a leak-free seal and secure sensor retention.

Stainless Steel Metallurgy

Designed specifically for compatibility with 304 and 316 stainless steel exhaust components, this weld-on boss prevents the galvanic corrosion and thermal expansion mismatches that can occur when mixing mild steel hardware with stainless tubing. The weld-on base is machined from solid stainless stock, offering excellent weldability and resistance to the oxidation and scaling common in high-performance exhaust environments. Once welded, it becomes an integral part of the exhaust structure, capable of supporting the sensor probe against vibration and heat stress.

Integrated Compression System

This kit is not just a bung; it is a complete mounting system. It includes the weld-on boss which features the necessary internal geometry to accept the included compression nut and ferrule. This design allows for the direct insertion of a 1/4″ EGT probe. As the nut is tightened, the ferrule compresses around the probe shaft, creating a hermetic seal and locking the sensor at the desired immersion depth. This adjustability is critical for centering the probe tip in the gas stream for accurate data collection.

Installation Best Practices

• Preparation: Drill a hole in the exhaust runner or collector corresponding to the pilot of the weld boss.
• Welding: TIG welding is recommended using Stainless Steel filler rod (e.g., ER308L) for the strongest, cleanest joint.
• Sensor Depth: Insert the probe to the center of the pipe before tightening the compression nut.
• Maintenance: Use anti-seize on the compression nut threads to facilitate future sensor removal.

Kit Contents

Includes: Stainless Steel Weld-on Base/Body, Stainless Compression Nut, and Ferrule. Note: Intended for welding onto stainless steel piping.