DKET
Expert Class
Posts: 189
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posted May 08, 2004 05:14 PM
 Edited By: DKET on 12 May 2004 10:08
stock exhaust can mod. PICS INSIDE
I pulled my stock can off yesterday at work . I removed the cat converter and punched 2 one inch holes in the mid plate that holds the ex gas transfer tubes . Now the ex gas has 2 one inch holes to escape from plus the regular S route .
For the 1 inch holes I used a piece of large rebar steel . One end was pointed like a pencil . It is actually used to anchor a satellite antenna for the US Army Stryker Brigade , HOOAH!
Airflow from the can exit is now roughly double what is was stock . And the sound is mucho betta . Sounds like an deep angry Ferrari on steroids . Oh and the cost , FREE .
  
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swft
Needs a life
Full throttle!
Posts: One MEEEEEELLION
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posted May 08, 2004 05:19 PM
Tsk tsk...Don't you know that tampering with yer exhaust is a federal offense? 
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DKET
Expert Class
Posts: 189
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posted May 08, 2004 05:30 PM
Thanks for the 411 . Since I do not live in the U.S. at this moment , I have no concerns . Besides a full system is on the list .
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swft
Needs a life
Full throttle!
Posts: One MEEEEEELLION
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posted May 08, 2004 05:33 PM
*grins* Just helpin' out!
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DKET
Expert Class
Posts: 189
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posted May 08, 2004 05:42 PM
No offense to you but I could use less help from all the clean air GreenPeace , tree hugger , dog and cat lover mofo's .
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Michael Lee
Zone Head
Purchase Ivy
Posts: 729
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posted May 08, 2004 07:12 PM
Thanks, may try with just one hole first.
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supraman95mb
Expert Class
Posts: 212
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posted May 08, 2004 08:30 PM
Can anyone dyno to see if removing the cat and drilling the holes actually works to our advantage. I dont see how it could possibly not add ponies, however some say that the ECU cannot compensate, etc.
I want to do this to my bike but just wanted to make sure I am not going backwards.
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02 Stroked 12R
95 Supra Single Turbo 750+ hp
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otto65
Novice Class
Posts: 95
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posted May 09, 2004 06:06 AM
DKET , must have been a busy day at work huh? But really ,how did you remove the cat. I had my pipe off and was debating boring thru the cat with a hole saw or drill bits. Tried to take the tip end apart but it looked welded together. thanks ,Otto
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Its all part of my master plan to rule these worlds
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dket
Expert Class
Posts: 189
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posted May 09, 2004 09:45 AM
Edited By: dket on 12 May 2004 02:58
cat convert removal
I used a large flat blade screw driver and a big hammer . I drove the driver in a plus config and kept going from the middle out . I also used a 12 inch Crescent wrench and hammer . Put the handle end down on the cat , hammer away . Eventually all was left was around a 1/4 inch around the circumference of the ring that holds the cat in place . I have a huge approx 3 inch hole now where the cat was .
After the cat removal I used a 24 inch long 1 inch diameter piece of rebar steel . It was already ground into a pencil point on one end . Is is used as a satellite antenna anchor for a 2.4 meter dish . I then drove the rebar through the mid-plate that holds the center exhaust gas tube in place . You will see what I am talking about when you remove the cat . My center plate was actually blue in color . Probably from the heat off of the cat converter . There is a center rib on the plade . I drove the rebar on either side of the rib . Drive the 2 holes opposite the center ex gas transfer tube .
VERY IMPORTANT !!!!!!
Use a dust mask while removing the cat . It makes a lot of cat dust when you are hammering that cat out . Cat is made of "unobtanium" metals and are surely bad for your lungs/health .
Also important use a 2x4 piece of wood to place the end of your ex can onto while hammering . This is so you don't deform the ex can exit tube . I removed the 3 allen headed fasteners on the can exit . That removes the ex exit tube cover . That way it will not harm that cover while hammering .
On a side performance note , I am 6 foot 235lbs. minus riding gear . Had a 20MPH head wind . I was leaned all the way forward . The top of 4th gear is approx 245 kilometers per hour . This is approx 155 miles per hour at the top of 4th gear . She came up in a hurry when I shifted to 5th .
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dket
Expert Class
Posts: 189
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posted May 10, 2004 01:51 AM
bump
just a bump for justoyz2
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salsa1
Needs a life
Posts: 5971
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posted May 10, 2004 04:44 AM
Edited By: salsa1 on 10 May 2004 08:22
Only concern is I asked myself what do I want to ride into dealer if I claim warranty work for any reason? I paid for 5 year warranty so I felt I will keep stock can stock if I ever need to put it on and possibly get slip on if I want better sound or bit more power.
I sure like the idea of modifying factory can for nothing tho...
Good job if it works for you.
I was wondering how to do.
I printed post/procedure in case ever need.
Thanks!
peace.
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andy
Expert Class
Posts: 220
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posted May 10, 2004 07:29 AM
quote:
Only concern is I asked myself what do I want to ride into dealer if I claim warranty work for any reason? I paid for 5 year warranty so I felt I will keep stock can stock if I ever need to put it on and possibly get slip on if I want better sound or bit more power.
I sure like the idea of modifying factory can for nothing tho...
Good job if it works for you.
I was wondering how to do.
I printed post/procedure in case ever need.
Thanks!
peace.
That shouldn't affect your warranty. Look at all the aftermarket pipes out there.
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frEEk
Administrator
ummm... yeah
Posts: 9660
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posted May 10, 2004 09:18 AM
the main ingredient in a cat is platinum actually, which i dont believe is a health risk (it's an inert metal like gold), but much of the dust is prolly sediment from the exhaust, which is gonan be chock full of nasties, so mask is a great tip!
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salsa1
Needs a life
Posts: 5971
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posted May 10, 2004 09:49 AM
Edited By: salsa1 on 10 May 2004 10:50
Hi there Andy;you are probably correct just got that info from a loose comment from salesperson at the dealer I purchased ZX-10R from.
I walked away believing I should not ignore comment. Ya want dealer to be on your side would ya need warranty work especially if claim could be questionable or challenged.
I will look into this and see. I would be happy to get about same results as $500.00 slip on just modifying existing can myself.
Been 12 years since last new bike purchase for me.
Have fun;good point.
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andy
Expert Class
Posts: 220
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posted May 10, 2004 02:43 PM
I'm right there with ya Salsa1. I'm willing to ask a dumb question before hacking peices off of my $11,000 bike. So here's mine:
The cat is the thing that looks like a honeycomb, correct?
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D
Needs a job
Posts: 3365
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posted May 10, 2004 03:06 PM
Yes - and it's in the front portion of the muffler.
The dealership would have to prove that whatever failure occurred was caused DIRECTLY by the modification (in response to bolt/slip-on or modded stock cans).
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andy
Expert Class
Posts: 220
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posted May 10, 2004 03:17 PM
Thanks D
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runninhorn
Expert Class
Posts: 442
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posted May 10, 2004 08:44 PM
here are the pics I just snapped, I took mine off tonite to try and perform the same mod--the cat converter is the honeycomb thing correct?
Id like to hone it out as big as the inlet hole..........doubt it could be done though........
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runninhorn
Expert Class
Posts: 442
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posted May 10, 2004 08:57 PM
Edited By: runninhorn on 11 May 2004 01:13
it looks just like the ceramic in cats.......
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dket
Expert Class
Posts: 189
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posted May 10, 2004 11:53 PM
cat removal
The honeycomb area IS THE CAT CONVERTER . It is not the other end of the can where the outlet exhaust gas tube is . The CAT is around 3-4 inches deep into the can . The cat honeycomb material will all come out . Like I posted I removed all of the honeycomb material but maybe an 1/8 to 1/4 inch around the retaining ring that holds the honeycomb in place . Again I have around a 3 inch diameter hole where the cat WAS . It now is roughly the same size as the cat side inlet . It takes some elbow grease to remove the cat material but all will come out .
Another good tip on the cat removal after you screw driver it out is to use a die grinder to remove the remaining 1/4 inch of cat material around the honeycomb circumference . Use a carbide bur like for porting a cylinder head . Also can use a Dremel Tool . All should be left is the honeycomb retaining steel ring . Again WEAR A DUST MASK WHEN REMOVING THE CAT HONEYCOMB MATERIAL !!!!
The second pic that runninhorn posted is the cat converter . First pic is of the exhaust outlet tube . This stuff is not rocket science fellas . Some guys are still questioning what and where it is .
How is the steelership going to know you did this mod ? For warranty repair work that is . The can after the mod looks totally stock . The steelership would have to do a NASCAR teardown to find it . Besides if I were to blame an exhaust system for failure which I never heard of BTW , I would blame a full system before this mod . Doubtful but if you ever have any probs with your steelership about warranty , go to another steelership .
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dket
Expert Class
Posts: 189
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posted May 11, 2004 12:03 AM
quote:
it looks just like the ceramic in cats. What about the big hammer and screwdriver method--Think that should work?
The hammer and large screwdriver is what I used to reomve the cat . Please read my post . You can get the cat hole the same size as the exhaust inlet .
I do this stock exhaust can mod to all my new bikes . Got to have something while the full systems are in production . The CBR954 was a bugger with the California mid-pipe sleeve BS removal .
I can snap pics of mine if you want to see . Just provide your email address and let me know .
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runninhorn
Expert Class
Posts: 442
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posted May 11, 2004 12:09 AM
Edited By: runninhorn on 11 May 2004 01:10
thanks for the info, id like to see the pics as ill be trying this tomorrow......
uthustler@yahoo.com
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dket
Expert Class
Posts: 189
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posted May 11, 2004 12:11 AM
quote:
the main ingredient in a cat is platinum actually, which i dont believe is a health risk (it's an inert metal like gold), but much of the dust is prolly sediment from the exhaust, which is gonan be chock full of nasties, so mask is a great tip!
I am sure that ANY form of metallic dust or exhaust dust is not a good idea to inhale . Be it platinum or any type of metal . Always when grinding or sanding wear a mask . Especially when porting a cylinder head and using a die grinder . You will have cast iron buggers if you don't .
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salsa1
Needs a life
Posts: 5971
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posted May 11, 2004 04:49 AM
Edited By: salsa1 on 11 May 2004 05:52
How are steeler going to know is asked? Just by listening to the engine. But Iam hip to going to another dealership ;done it before .
I will probably do modification when I feel ok about it . I would not mind some pictures of modification; I want to avoid getting carried away and taking too much off (just a thought).Sshould become obvious once I start the work with your instructions.
I like the idea ;I was wondering who on forum could give me info on how;good deal.
Thanks; Dket you have mail.
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MAVRIK
Novice Class
Posts: 39
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posted May 11, 2004 04:52 AM
definitely thanks for the info...could i get a pic sent to me....thanks
justin_yzfr1@yahoo.com
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