I am about to undertake the EGR removal (well really, just fitting the blanking plate). What is the best method to clean the gunked up pipes? Another question is...what can I make a gasket from? Any advice will be digested with pleasure. J

Clean the pipes with engine degreaser, soak overnight is best. Holts make exhaust sealant in a tube, white stuff, works well. Or don't bother if your plate is thick and flat, chances are it won't leak anyway.