core bit is not worth a dam, won't get it all out. 1 inch x 16 inch paddle bit and a bit of pry bar action and it's gone, all of it.

 

Yep...Thats what i did.....i noticed much less heat, better sound even with the stock pipes and no felt change in performance.

 

After looking at mine fore a couple of minutes I decided to cut pipe in two and drill it out. I will have a local guy weld it for me for a case of his favorite beverage. After about an hour of drilling, digging, scraping, and polishing I can't see how a guy can get it out and clean with a paddle bit. I did do something easier on the second half of the dig out. I used a small drill bit and repeatedly drilled around the perimeter of the cat material and wiggled the bit from side to side and by the time I got back to the place where I started it pulled right out. Then scraped and polished the inner wall and she was good.

 

Been lurking here and on other forums for the Decat. Planned on doing the door approach as I couldn't see cutting it in half. I kept looking at the header after I removed it and kicked around drilling it out (like I did with my '88 Alfa) but was gonna go with the tried and true method all the guys were suggesting until I came across this post. Seeing it could be done I decided to try knowing I could always cut the door if I had to.

It was a piece of cake - like noted above, 30 minutes with a $10 spade bit and some scraping with a homemade rod/washer set up cleaned it near perfect. So happy I had to put it back together to hear it run. OBTW '12 Roadie Ultra 103 is my new ride.

Now I just gotta figure out all the tuners, XiEd, etc. before moving on with more engine mods.

Wanna thank all you guys for the help. Love it when I can wrench on my ride and spend 10 bucks!
Ciao

 

I just took my pipe off my 2013FLHX 2 nights ago and used the window technique method. The catalyst material was a motherfuXXer to remove - unsure how you folks do it with a drill!!!!

I scraped as much out with a screwdriver, and then i used a die grinder and made it smooth as could be.

Next goal was to re-weld panel and make it look as factory as possible. It took a little time but with help from a Uncle who has a Metal Fab shop - see the results: