Making the EGR polishing sticks...
 


Needed:

1ea 36" long 1/4" oak dowel (not Poplar) cost: approx 60 cents. Home Depot.

Dremel and abrasive cut-off disc.

Cut the sticks to 5" length

Cut thru center near tip half from one side til it comes out the other side. Then flip stick and finish the slot from that side.

Abrasive media:
You can use anything from sandpaper to ScotchBrite pads cut to size for rough finish. Abrasive pads can be pushed thru or spiral-wrapped if you have some aerosol contact cement.

Polishing media:
You can use cloth, paper towel or even cotton balls with a polishing compound like the Dico Jewelers rouge in the pic (Home Depot). Or commercially available polishing compounds like the Eagle One in the pic which is a cotton ticking impregnated with jewelers rouge (Pep Boys).

Keep the stick with media-wrap loose fitting in the EGR bore, "high-speed/light-friction" rather than the other way 'round. Make it too tight and it'll break off inside. No harm done but then you get to push it out from other side and you get to make more sticks. Use light oil for sandpaper, ScotchBrite or jewelers rouge. Only clean from the EGR valve side. And don't go any deeper into the bore than where it dumps into the IM's throttle body flange. No need to sand or polish the EGR sensors threads away on the opposite side.

Go forth and polish!!