Okay - I have been convinced that it is a good idea to upgrade/delete the cooler. I would go for the upgrade because I move around a lot and never know what state I may end up in. So here is the info on Sinister and BulletProof.

From you guys that have done these conversions or know guys that have done them which one would be the best?

Basic Solution(TM) for Ford 6.0L Powerstroke With Sinister Upgraded EGR Cooler

Sale Price: $690.00 (+$35.00)Item Number: MKM-BS-UC-6.0
Manufacturer: Sinister Diesel
Manufacturer Part No: MKM-BS-UC-6.0
Availability: In Stock
04-07 6.0 Powerstroke Upgraded EGR Cooler
Customers in heavy smog tested counties have been asking for it and here it is. A Upgraded EGR Cooler looks and fits like stock but without all the factory egr cooler problems. We have removed the factory honeycomb material inside and replaced it with a series of stainless steel tubes. The tubes allow the exhaust gas to flow more freely and faster eliminating a chance of clogging. The Sinister Upgraded EGR Cooler is tig welded and every cooler goes threw a series of pressure test to ensure your getting a leak proof cooler.
• Does not Require Complete Removal of Intake Manifold saving hours of install time • Direct Replacement of existing EGR Cooler • Works great on vehicles in heavily smog tested counties • Pressure Tested TIG Welds Guaranteed not to Leak • Includes detailed Installation Instructions
• Factory honeycomb is replaced with bigger stainless steel tubing which allows for better exhaust gas flow into manifold
• Will not throw a Check Engine Light on any year 6.0 Powerstroke
Oil Cooler
Ford newest version of oil cooler for the 6.0 powerstroke. Thicker internal fins to minimize chance of cooler failure. This is a new Ford OEM (not re-manufactured) oil cooler The Oil Cooler includes new gaskets for easy installation
Oil Cooler Screen
Ford recently changed the oil screen material from a cloth screen which came on all 03-07 6.0 motors to a stainless steel screen. This change allows better filtering of particles in oil and will not tear like the original cloth screen.
Intake Gaskets
Removal of the intake manifold is necessary to install a oil cooler. In the basic solution we supply you with a new set of intake manifold gaskets.
Turbo Bolt / O-Ring Kit
New mounting bolts for re-installation of the turbo and pedestal. New spacer washers and line clip. New O-Rings for the oil return and pick up lines going to and from the turbo. Also included is a new paper gasket that fits in-between the turbo and turbo pedestal.

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Semi Bullet Proof Package, Ford 6.0L Diesel
Complete Kit - Includes everything you need to replace your EGR cooler.
Warranty Note: this package includes a STOCK FORD OEM oil cooler. This part has a high failure rate (including new in-the-box parts) and therefore is covered by the Ford parts-only warranty.
The stock Ford OEM oil cooler comes with the High Pressure Oil Pump Filter Screen.
Starting From $825.00 •Upgraded Bullet Proof Diesel EGR Product, Round or Square, Delete or Cooler
•Engine Oil Cooler, Ford, Stock
•EGR Gasket Set Complete, Ford, Stock
•Turbo Mounting Hardware, Stock
•High-Pressure Oil Pump Filter Screen, Ford, Stock
•Note: There is a fully-refundable core charge associated with this product that will be added to your total at check-out.

 

I like the deletes myself, however if you might end up in a state where they will check it youll probably wana do the upgraded cooler. Bullet proof is very well known and seems to be a quality product. We use the sinister delete kits here. I have an excursion behind me right now that has a leaking bullet proof cooler on it and customer is having us delete it. I dont know how many people have had problems with upgraded coolers but on this truck it appears that its not a permanent one time egr cooler fix.

 

What are your emissions requirements? This isn't like removing the off road x-pipe in your Fox Body for smog, ya'know. IF you only need an ODBII plug in check and a visual for emissions, you MAY be able to get a program that allows stock tuning while it eliminates CEL for EGR insufficient flow on a plugged EGR cooler. This would be the same as running a MIL eliminator on a non-catted 03 GT Mustang.
A plugged cooler is exactly that, you pound freeze plugs into it, tack weld for security and reinstall, EGR effect defeated for next to FREE. The EGR cooler takes exhaust gases from the up pipe and plumbs it back into the intake. Removing the cooler gives you throttle response and helps your EGTs peel off faster. Just make sure you replace the red piece of hose and those poorly designed, leak prone, OEM "clamps" if you only plug your cooler.

Personally, if you can get away with using a delete, I like the ones that have the block off welded to the return coolant pipe and have a stainless up pipe. Just remember, the EGR cooler is the problem, NOT the EGR valve. Point being, you don't need to remove the valve. However, having an 06, you are going to need an SCT to eliminate the CEL that is going to come on. But I think ALL 6.0 owners should have an SCT now that I have one.

 

You can get EGR delete's for about $150 on ebay.

Those sinister kits are overpriced IMO. But I guess you pay for the convenience of one stop shopping.

If I was going to keep an EGR cooler, I would certainly buy a bulletproof, heard nothing but great things from them.

 

I did the whole EGR Delete on my truck but if i was going to do the upgrade i would have gone with the bulletproof cooler. This is the site i got my EGR delete from http://www.custom-diesel.com/ it ran me 147 shipped