Cat removal
Tourer
Joined: Jul 2011
Posts: 267
Likes: 4
From: Jacksonville, NC
This topic can be found using the search box, i've removed many Cat's and taken them to local shop to weld it back together. As long as the Welder knows what he's doing he'll know what rod to use and not burn/blow through anything, i'm no welder which is why i had someone else do it for me (you didn't mention if you were going to try to weld it?). My prefered welder uses a tig welder and since i always cut at the factory welds you wouldn't know it was cut open unless i told/showed you. Another Welder i used at the last minute used a mig welder. I hope this helps.
Extreme HDF Member
Joined: Jun 2011
Posts: 10,216
Likes: 224
From: Glendale AZ
I cut open the front of it and carved it out like a pumpkin removing every bit of the honeycomb **** inside of it with whatever I had available to do the job. Don't do it half assed, if your not going to cut it open just leave it alone. Try to imagine carving out a pumpkin thru a 2" hole.....exactly.
Take it off the bike and put it on a bench vice before you carve it out or your going to hurt your bike....it's a big mess and you don't want your scoot anywhere near it when you go to town.
Take it off the bike and put it on a bench vice before you carve it out or your going to hurt your bike....it's a big mess and you don't want your scoot anywhere near it when you go to town.
Last edited by TUCCI; Jul 28, 2013 at 06:58 PM.
Club Member
Joined: Sep 2010
Posts: 18,776
Likes: 42
From: Walker WV by way of NEW YORK CITY
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Road Master
Joined: Oct 2012
Posts: 1,240
Likes: 82
From: Columbus, GA
16" long 1" spade bit and a good drill.
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Elite HDF Member
Joined: Oct 2010
Posts: 3,504
Likes: 12
From: DOWN SOUTH
Since nobody told you, Welcome to the forums Screamer. When you cut your cat out, cut along the length of the pipe in the oval big middle part of the pipe (thats where the cat is) cut a window out of 1/2 of that section, dig all the cat material out then clean with a flapper wheel or something, take it to a muffler shop and have them button it back up for less than 50 bucks, cheap DIY. Dont just cut the pipe in 1/2, you will loose length when you put it back together and things wont line back up. I am attaching the link for a thread that explains how to gut the cat DIY. If you do not feel like messing with it, you can get one already done from fleabay for round 100 shipped to your door, or google american customs, they do this also and they gut stock mufflers and have a link with pics and tools needed for exhaust removal and assembly. Also you can use the search feature on the top right by the advertising button under the fuel moto banner, type in what you want, click show threads hit go, whatever you are searching for will pop up. Hope this helps you out, stay safe out there..
https://www.hdforums.com/forum/touri...with-pics.html
http://www.americancustom.com/media/news/AmerCustom.pdf
Supporter
Joined: Jul 2007
Posts: 2,196
Likes: 10
From: Shenandoah, TX
I would use 3/32 mild stainless. That way, it the bead want rust up on ya.