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Bro that is seriously impressive, a very clever appraoch to the cat removal, you could probably get away with an even smaller cut out section. I've been fabricating for a long time, and I never even considered doing it that way. Way to think outside the box.
Thanks. I never mentioned the fact that it was a biotch to get the cat out but I just took my time.
I'm sure the cat removal was a little more time and labor intensive, but you accomplished the job without affecting any of the original dimensions or causing any alignment issues. I would say that you have figured ouy the best way to do the cat removal. Your method offers up new possibilities for me to re-engage my OEM header improvement project, thanks again for sharing.
Here is a picture of how I did mine. I used a Dremmel to cut the pipe and since it wasn't cut in half I never had to worry about aligning the 2 halves and the pipe not fitting to the bike afterwords.
Wow, great idea. I think I may be doing it the same way. Thanks for the pic.