When you click on links to various merchants on this site and make a purchase, this can result in this site earning a commission. Affiliate programs and affiliations include, but are not limited to, the eBay Partner Network.
Sorry Bill, but you are simply not going to "drill" out the cat material. It's way too stubborn for that. Additionally, the limited design of the stock header is way behind a properly designed 2-1-2 stainless header. No contest. But many settle for a de-catted stock pipe either for money issues or whatever, so each to his own.
I mentioned drilling because there are a lot of people that seem to have had sucess with it. I cut a coupon in mine and welded it back in.
I went this way because there was a dyno on the FuelMoto page that showed a comparison between a 2009 Limited with stock head pipe (no Cat) and a Jackpot. There was only around 1.8 HP difference between the two. Not worth the 500.00 to me, especially since I plan to do no other mods than the SE aircleaner, PC V and slipons. One of the guys at FuelMoto also told me I would not see any real difference with just those mods.
Also, the OP was trying to pass an emissions test without a lot of expense and mods plus having to change out the header every two years. My suggestion was a possible way around having to keep switching headers and still get some performance and sound.
7 Surprising Harley-Davidson Products that Are Not Motorcycles
Slideshow: The bar-and-shield logo shows up on far more than motorcycles, some of the company's most unexpected products have nothing to do with riding.
Slideshow: From the troubled AMF years to modern misfires, these bikes earned reputations for reliability issues, questionable engineering, or disappointing performance.
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?
Slideshow: The Swiss custom shop has taken a Harley Softail and stretched it into something so long and low that it looks closer to a rolling sculpture than a conventional motorcycle.
Engraved Rebellion: Inside Bundnerbike's Glam Rock II
Slideshow: A standard cruiser becomes an intricate metal canvas in the hands of a Swiss custom house known for pushing Harley-Davidson platforms far beyond their factory brief.
Slideshow: Harley-Davidson's challenges aren't abstract; they show up in dropping shipments, shrinking dealer traffic, and strategic decisions that aren't yet translating into growth.