Cat Converter Removal
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Road Master
Joined: May 2008
Posts: 907
Likes: 8
From: Greeneville, TN
Cat Converter Removal
I have a friend that has an '11 Ultra. The catalytic converter is in the header pipe junction. A dealer told him he could drill this out and run cooler. The dealer said he did it without problem. Anybody else done this?
Tourer
Joined: Mar 2011
Posts: 469
Likes: 2
From: Downriver, MI
My salesman told me the same thing. Said he drilled his out with a paddle bit. Will be interested in any replies as I'm thinking about doing this when I install slip-ons in the spring.
Seasoned HDF Member
Joined: Feb 2007
Posts: 10,602
Likes: 721
From: Bellevue, NE
That cat completely fills the pipe in the collector area. I cut my pipe to get to mine, and I'm glad I did. A spade bit can remove some of it, sure, but it'll leave a bunch behind and probably a mess in there. I wouldn't want to take the chance that some of that debris gets sucked back in though an exhaust valve. Cut the pipe, remove the cat, re-weld the pipe IMHO.
Run a search. Been many threads on this, including a detailed "how to" with pics and all.
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Road Master
Joined: Jul 2011
Posts: 1,020
Likes: 2
From: Canton, Ga
I read at one time on here someone used a very long concrete drill bit, almost like a hole saw. I had one of my techs at work attempt to remove mine, he used a drill bit and made more work for himself. Finally he listened to me, cut the pipe open, removed the guts and welded it back shut.
Outstanding HDF Member
Joined: Apr 2007
Posts: 2,884
Likes: 75
From: Goldsboro, NC
I have pictures that will convince you,, a 1.5" hole saw won't be enough,,
Here's the plug you'll get,,
Here's the pipe before and after the hole is drilled,,,
HERE IS HOW MUCH CAT IS IN THE HEAD PIPE,,,,,,
Here's the plug you'll get,,
Here's the pipe before and after the hole is drilled,,,
HERE IS HOW MUCH CAT IS IN THE HEAD PIPE,,,,,,
Outstanding HDF Member
Joined: Apr 2007
Posts: 2,884
Likes: 75
From: Goldsboro, NC
Now, I haven't done this to mine, yet,, it's going to happen probably in the spring, when I have an outbuilding to set my welder up in,, and a place to really work on the bike.
Trending Topics
Someone suggested just as easy as replacing with a header pipe from a 09' model. They should be easy to come by. Question is will it be a straight bolt on with no modification?
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Outstanding HDF Member
Joined: Apr 2007
Posts: 2,884
Likes: 75
From: Goldsboro, NC
Father time,, I believe there's a few differences in the sensors, (O2) however for those of us with a '10,, it was the only good year for Street Glides, coming with the stock 2-1 exhaust! 
So an 09 would be a step backwards for us,, if you have an 11 or 12, then the 09 would be 2-2 also,, and likely a direct swap....
Danny, where in the world do you get the information that the CAT is not that restrictive? Also, yes, these are not Turbo Diesels,, and a straight pipe isn't the way to go,, but the MUFFLER will supply all the back pressure these motors need, now you'll likely have to run a new MAP on the ecm,, but they will run MUCH MUCH COOLER,, Holy cow,,,,,
You think your Ultra runs perfect without it??? Ride a 96ci that's got aftermarket exhaust, intake and a tune on it,,,, night and day sir,, night and day..... I am not happy with my 10 SG now at all! LOL,, I want something, a 103, 107, at least cams, intake and exhaust, with a MAP... SOMETHING!
So an 09 would be a step backwards for us,, if you have an 11 or 12, then the 09 would be 2-2 also,, and likely a direct swap....
Danny, where in the world do you get the information that the CAT is not that restrictive? Also, yes, these are not Turbo Diesels,, and a straight pipe isn't the way to go,, but the MUFFLER will supply all the back pressure these motors need, now you'll likely have to run a new MAP on the ecm,, but they will run MUCH MUCH COOLER,, Holy cow,,,,,
You think your Ultra runs perfect without it??? Ride a 96ci that's got aftermarket exhaust, intake and a tune on it,,,, night and day sir,, night and day..... I am not happy with my 10 SG now at all! LOL,, I want something, a 103, 107, at least cams, intake and exhaust, with a MAP... SOMETHING!