On the fence with taking my headpipe off and gutting the cat or buying one off Ebay. I am not a welder but can do it (Im so so). I see some on Ebay that people have done without cutting. How did you guys do it?

 

I read a post a long while back the someone took some sort of "core drill bit" and drilled through the crap in muffler connection. I'm not sure how good doing it that way worked out. Do a search because there are MANY posts with this same subject that might help you.

I'm no welder either but i cut mine with a "sawzall" at the weld closest to the header 2 yrs ago. It took me about an hr to gut it and then took it to the local welder and he tig welded it for me for $40. You can't even tell i gutted it either. I've done it 3 times already and i'm gutting another one as a spare. I even gutted my mufflers a yr and a half ago with a dremel.

 

274 posts right here on this subject on this site.
https://www.hdforums.com/forum/touri...with-pics.html

Try using the search tab in the middle of the tabs on the upper part of your screen and then type in what your looking for.
You'll be amazed at all of the info.
Not much new info on what you are asking.

 

Drilling it out was easy. Took maybe a half an hour or 45 minutes to do. I started with a hammer drill and a long cement bit I had at work, but it didn't work too well. Ultimately I used a 16" long 1" wood boring bit in a regular drill. I also had a bore scope so I could see that I got all of the material out. There was one small section that was really stuck to the pipe that took some convincing, but I got it all out.