Has anyone removed thecatalyst from a muffler?

 

Yes, I did this to a pair of '06 CVO pipes.

I was able to pound/bore through the cats (the catsare a soft aluminum type screenmaterial about 1.5" thick) using a 1.5" diametergalvanized pipe (make sure it fits into the muffler inlet and the pipe is not real thick walled). I cutthe pipe at a 90 degree angle toabout 18' long. Thenwith a bench grinder,sharpened the end of the pipe, real sharp. On the other endof the pipe Idrilled two 1/2" holes across from each otherandpushed through, and bolted down, a 12" longbolt to form a "T" handle. Once completed, I put the muffler on the gound with the inlet side facing up. Make sure you use some thick carpet or paddingas a cusion for the outlet end. I inserted the sharp end of the pipe into the inlet (this is where the cat screen is) I used small sledge hammer to pound into the cat material. I periodically sprayed in WD40 to provide lubrication. Every few pounds I use the "T" handle to twist around the pipe so it didn't get lodged into the material. After about 5 minutes or so of pounding and spinning I broke through the material. Since I had been makeing sure the pipe wasn't lodged in the material,I was able to pull out a perfect "plug" of cat material. Once out, there was a perfect, clean 1.75 (approx) hole straight thourgh the cats.

Once done, I was very pleased with the performance and sound of the muffler. It was a little bit louder than before with a nice growl when ramping up.

 

Thanks so much thats just the answer I was looking for.

 

You are welcome. Worked pretty slick.

I know other people have done the same thingusing a concrete boring bit. But I priced it out, and it was like $50 for the part. I just lopped the pipe of my volley ball net posts.

 

Hey Pumba11 ... after I read your post about how you creatively removed the catalyst material from your '06 CVO pipes I got inspired to try it myself for my '08 CVO SEUC. First step was to find someone else's take-off mufflers so I could preserve my own (just in case!). I found a pair on Craigs List for only $50 from an '07 CVO SEUC and snapped them up ... then the next step was to find a way to cut through the catalyst material since I didn't have a convenient volleyball pole lying around! So, I went to Home Depot and boughtthe deepest1 5/8" hole bit (for metal of course) and a long extension so I could get into the inlet part of the pipes.After discovering that I didn't have any WD-40 around, Iraided the pantry for some olive oil which worked to keep thehole bit lubricated. Even with a simplehome cordless drill, after about30 minutes I had perfect"plugs" of catalyst material pulled from both pipes!

This weekend I willslip these on the scoot and see/hear/feel the results. Just curious ...mybike is one of those "closed loop systems," do you have to do anything elseto tune the bike once your cats were out?

 

BonsaiBob,

Good work on the creative wrenching!

Luckily I have a carbed bike and a tweek on the enrichment screw was all I needed. I have already jetted the carb formy SE mufflers I had on before these, so it didn't take much.

I am very please with the mellow sound I have gotten out of mine. Still in rush hour they arelittle too quiet. But MUCH better than the stockers that came on my bike.

I hope you enjoy them and let me know what you think after you ride them.

 

Well, since Pumba11 is a traditionalist with a carb I have to ask for other advice ...

Can I just slip on the mufflers that I drilled out the catalyst material onto my '08 SEUC ... or do I have to arrange for some tuning of the air/fuel mixture? I am not mechanically inclined, and have never had a "closed loop system" with O2 sensors! Any help certainly appreicated!

Thanks!

 

You won't have to worry about the AFRas long as you leave the stock air filter in.

 

Thanks ... since I don't plan to change the air filter right now I went ahead and slipped the "catalyst free"pipes onto the scoot today. Unfortunately, it started to rain about the time I was finishing up so I haven't road tested the sound and performance yet ... but sitting in the garage at an idle the pipes are definitely a lower (deeper) rumble tone but only a slight bit louder than stock - which is exactly what I was hoping for. Revving the engine up gives a nice bark without being hard on the ears. So far, I am pleased with the results but the real test will be highway speeds. The rain isn't supposed to break here until the weekend, so it will be a few days before I know if they will stay on! All told, my $70 investment seems to be working out just fine ... andfor now at least, I get to keep the stock look of the CVO SEUC with a more authentic Harley rumble!