Brozz catalytic converter removal

[MOTOXtreme]

Ok, this was WAY harder than I imagined it would be. Was hoping to make one cut and get it all out that way. Needless to say, that didn't work. You can see I tried my air hammer and it simply made a mess of it.

Ending up cutting it out on both sides and welding everything back up. Weld looks hideous but it works. This was mainly a test to see if there was any performance gain. I believe there was, but maybe I'm just wanting there to be???

I now occasionally get some light pop pop popping when I decelerate and I think I may need to go up a jet size. I need to inspect the plug and see how its running.

[dpl096]

I don't recall who but someone else removed their cat too but the cut a panel out on the engine side of the body and then dug the material out. Welded the panel back on and from the outside no one can tell it was modified. Seems to me he was from Alabama and ended up selling the Hawk over registration/title issues with the state.

[BigWeld]

Hey! I removed my Brozz's cat today, too!

[MOTOXtreme]

Hey! I removed my Brozz's cat today, too!

Cool. Figured it darn sure couldn't hurt. Let me know your thoughts after you put some miles on it with it removed.

[MOTOXtreme]

I don't recall who but someone else removed their cat too but the cut a panel out on the engine side of the body and then dug the material out. Welded the panel back on and from the outside no one can tell it was modified. Seems to me he was from Alabama and ended up selling the Hawk over registration/title issues with the state.

You couldn't pay me to dig this stuff out :). I tried and it was not fun.

[Weldangrind]

It'll most likely need a couple of sizes bigger on the main jet after a cat-ectomy.

[pete]

since you had the pipe open why did you not
turn the cat chamber into a power bomb ?




..

[old kid]

you can do this in one cut if you cut the cat. converter in the center and remove the two halves, i punched a 1/2" drill thru them and pulled the rest out with vise grips. I would also suggest installing the pipe back on the bike and tack welding the two halved back together. make sure they are where they need to be.

also some black heat wrap around the header pipe will cover it up if your worried about how it looks.

[MOTOXtreme]

since you had the pipe open why did you not
turn the cat chamber into a power bomb ?

..
This was just a test really to see if there was anything gained from it's removal. I did get to see how heavy the stock exhaust is. So I'm probably ordering the aluminum exhaust soon.

[JerryHawk250]

That double wall catalytic converter looks like it was a challenge. But the end results will pay off. Rejetting will be needed. On the Brozz it might be easier just to cut it off and put a piece of pipe.

[Azhule]

Did you remember to grind down the mountain welds on the inside of the header pipe (engine side)... most of these exhausts also have several huge crappy welds on the inside of the pipe that need ground down and circled out a bit... can get upwards of 30% bigger diameter on the pipe depending on how bad those welds are... our bike had one that was extremely restricted :tup:

[MOTOXtreme]

That double wall catalytic converter looks like it was a challenge. But the end results will pay off. Rejetting will be needed. On the Brozz it might be easier just to cut it off and put a piece of pipe.
Yes I agree, I thought the same thing. If I had pipe there to work with i would have.
Did you remember to grind down the mountain welds on the inside of the header pipe (engine side)... most of these exhausts also have several huge crappy welds on the inside of the pipe that need ground down and circled out a bit... can get upwards of 30% bigger diameter on the pipe depending on how bad those welds are... our bike had one that was extremely restricted :tup:
Hmm, i peeped in there but didnt see anything alarming. Actually the factory welds looked great everywhere I inspected.

[Megadan]

If you are worried about the welds being ugly after doing this sort of work, then take a flap disc and smooth out the welds a bit before you paint it. If your welds are good, then you could take the excess bead down to flush and it will never look like it was welded in the first place. Otherwise, header wrap and call it good.

[JerryHawk250]

Yes I agree, I thought the same thing. If I had pipe there to work with i would have.
I would of done the same but didn't have a piece of pipe either.

[Azhule]

"Grinder and Paint"

....

"Make me the welder I ain't" :hehe:

Here's a pic of what I was talking about... ours wasn't the worst I have seen but it was still really bad

http://www.chinariders.net/attachment.php?attachmentid=5462&stc=1&d=1460946481

Just horrid on the inside of my factory pipe :wtf: ground it down and made it round...

[JerryHawk250]

I would say that is bad. lol My HAwk had clean welds. Must of had the more experienced 12 year olds welding that day :hehe: "Grinder and Paint"

....

"Make me the welder I ain't" :hehe:

Here's a pic of what I was talking about... ours wasn't the worst I have seen but it was still really bad


Just horrid on the inside of my factory pipe :wtf: ground it down and made it round...