Dezrik
Follow me for adventure!
Lifetime Member
Tonight I decided to pull the muffler and delete the cat. I heard that it helps with a small amount of power and gets the heat out of the exhaust faster.
Safety FIRST, the reason I mention this is because the Dust/Cat materials are very bad to breathe in, This is why I did not want to "Break up" the cat material, If you do decide to do it with this method USE A RESPIRATOR!!!! Then throw the filters away!
First remove all the heatshields, you will reinstall these later
The first cut I made on the Larger tapered side, Reason being is that you'll have something to hang on to when your trying to slip the cat out of the muffler (Press fit but just tight enough to make it a task), You'll have to make two cuts, Ill go over that later. I cut it about 1.5" from the heat shield mounts, It honestly could be anywhere it tapers but I think 1.5" is a very good place to cut.
The cat is pressed into the muffler side of the on the big end, Just tight enough that it doesn't slip right apart, I used a combination of my bench and a rubber hammer and was able to free the cat. This is what that should look like once freed.
Now the second cut I had a idea about where the cat should be cut without getting into the cat core. a little research showed it was about 7.5" From the flange to the cat media. I decided to cut it at the 7 to 7.25" mark, that gave me about 1/4 of room to work without hitting the cat media.
Now with that second cut made, you should have something like this, the cat cut perfectly. Could even be reused? Haha. Now where my finger is pointed is why you can't just make one cut at the narrow side, the weld keeps you from pulling it through, right at the weld is where the cat media begins!
Now that its removed its time to reinstall, I choose to put a piece of 2.5" diameter pipe. My thoughts are that if you didn't install a piece of pipe in place of the cat there will be some added back pressure. Thats exactly why Im deleting the cat in the first place. This is what it looks like this inside.
Here is the narrow side and you can see the Oxygen sensor also.
Now I cut the 2.5" Exhaust pipe the exact same length as the cat I removed (I Forgot to take a measurement but will update that measurement in a few days). I pressed it back into the muffler side with just a hammer, test fitting the narrow side as I pushed it in.
Heres a shot of me test fitting it, I did use a die grinder to open it up slightly so I could weld the new pipe in, I think it would eventually rattle inside, this is why I chose to weld it in, I used a die grinder again and made small notches so I could weld it to the cone.
One last test fit before welding into place!
Now the easy part, Welding it all back together. (Sorry my welds look like crap, My welder is too large to weld up thin steel. I did the best I could with it at its lowest settings LOL!)
Boom end result, Will it void warranty, yes probably (My warranty is well up). Could they tell you deleted the cat without really digging in, Probably not. It still has a spark arrestor so we are in the clear there, If your BLM/Forest service guy wants to check
.
How hard was it, Pretty simple once you know where the cuts should be made, and your decent at welding!
Safety FIRST, the reason I mention this is because the Dust/Cat materials are very bad to breathe in, This is why I did not want to "Break up" the cat material, If you do decide to do it with this method USE A RESPIRATOR!!!! Then throw the filters away!
First remove all the heatshields, you will reinstall these later
The first cut I made on the Larger tapered side, Reason being is that you'll have something to hang on to when your trying to slip the cat out of the muffler (Press fit but just tight enough to make it a task), You'll have to make two cuts, Ill go over that later. I cut it about 1.5" from the heat shield mounts, It honestly could be anywhere it tapers but I think 1.5" is a very good place to cut.
The cat is pressed into the muffler side of the on the big end, Just tight enough that it doesn't slip right apart, I used a combination of my bench and a rubber hammer and was able to free the cat. This is what that should look like once freed.
Now the second cut I had a idea about where the cat should be cut without getting into the cat core. a little research showed it was about 7.5" From the flange to the cat media. I decided to cut it at the 7 to 7.25" mark, that gave me about 1/4 of room to work without hitting the cat media.
Now with that second cut made, you should have something like this, the cat cut perfectly. Could even be reused? Haha. Now where my finger is pointed is why you can't just make one cut at the narrow side, the weld keeps you from pulling it through, right at the weld is where the cat media begins!
Now that its removed its time to reinstall, I choose to put a piece of 2.5" diameter pipe. My thoughts are that if you didn't install a piece of pipe in place of the cat there will be some added back pressure. Thats exactly why Im deleting the cat in the first place. This is what it looks like this inside.
Here is the narrow side and you can see the Oxygen sensor also.
Now I cut the 2.5" Exhaust pipe the exact same length as the cat I removed (I Forgot to take a measurement but will update that measurement in a few days). I pressed it back into the muffler side with just a hammer, test fitting the narrow side as I pushed it in.
Heres a shot of me test fitting it, I did use a die grinder to open it up slightly so I could weld the new pipe in, I think it would eventually rattle inside, this is why I chose to weld it in, I used a die grinder again and made small notches so I could weld it to the cone.
One last test fit before welding into place!
Now the easy part, Welding it all back together. (Sorry my welds look like crap, My welder is too large to weld up thin steel. I did the best I could with it at its lowest settings LOL!)
Boom end result, Will it void warranty, yes probably (My warranty is well up). Could they tell you deleted the cat without really digging in, Probably not. It still has a spark arrestor so we are in the clear there, If your BLM/Forest service guy wants to check
.How hard was it, Pretty simple once you know where the cuts should be made, and your decent at welding!
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