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  1. #1

    Harley Catalytic converter removal "Catectomy"

    I recently bought a used header pipe for my ultra with the intent of conducting a “catectomy”. Here are some pics and a description of what and how I accomplished it.

    First , I made the cuts across the area of the header where the cats are, using an angle grinder with a cutting wheel. I didn’t need to have the cuts quite so far apart, but I wanted to insure that I had room to get into the cavity once it was opened up.

    IMAG0070.jpg


    Next I made the cuts lengthwise along the cat area.

    IMAG0071.jpg

    Be cautious when you cut near the mounting bracket. You can see here where I nicked it slightly.

    IMAG0072.jpg

    Once the cuts were complete, I pried the cut out off with a large screwdriver to expose the cats.

    IMAG0073.jpg

    This is where it gets fun!! I took a chisel and hammer and started chiseling out the cat material. I don’t know for sure, but have read on a couple other places, that this material is very hazardous. The edges are extremely sharp, so I definitely recommend using gloves while doing this.

    IMAG0074.jpg


    Once I got all the cat material out, I just scraped it as best as I could with the chisel and a putty knife. I figured that if I couldn’t scrape it out, I wouldn’t have to worry about it coming loose later.

    IMAG0075.jpg

    This last pic is looking into the end of the header to where the cats were.

    IMAG0076.jpg

    The next thing I did was to take it over to a friend’s house and tig weld it all back together. Then I came home, removed the OEM header and replaced it with my new “catless” header.

    As a part of my stage 1, I also purchased a 2” re-core kit from Fullsac, and installed those also.

    My first ride was up to Brunswick yesterday to meet JoeSombody. (About 100 miles round trip)

    The amount of heat that is NOT there anymore is absolutely amazing!

    The next step in the stage 1 mod is to install the Dobeck Gen 4, and a heavy breather. Hopefully that will happen this weekend. I’ll take pics of that and post them up too.
    Wayne
    Past Master 1995
    Old Fort Lodge 420
    Summerville, SC

    "Of all the things I've lost, I miss my mind the most" Click here to enlarge

    Sometimes it takes a full tank of gas before you can think straight.Click here to enlarge

    2010 Ultra Classic - Flame Blue pearl & Brilliant Silver Pearl

  2. #2
    New Member Liaison Tom's Avatar

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    Great job ..,,skin the cat. '.,-, TX for taking time to post & document ..',:-) :-)
    May I be "the least in the household of God."...

  3. #3
    Great post.
    My memory's not as sharp as it used to be.
    Also, my memory's not as sharp as it used to be.



  4. #4
    Co-Founder Hobbit's Avatar

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    Great job awesome write up now go enjoy the less heat mode of the bike Click here to enlarge
    Click here to enlarge
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  5. #5
    Moderator Clint's Avatar

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    Nice work Wayne..... And thanks for the write-up and pics. I think this will inspire other cat owners to take this on.

    So........ any noteworthy difference in sound?
    Click here to enlarge ALWAYS QUESTION AUTHORITY!!

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  6. #6
    Click here to enlarge Originally Posted by Clint Click here to enlarge
    So........ any noteworthy difference in sound?
    Yeah, It is slightly louder, but not enough to drownd out the stereo. The biggest difference is the deeper/throatier tone. And the best thing is, the wife likes the way it sounds now too!!
    Wayne
    Past Master 1995
    Old Fort Lodge 420
    Summerville, SC

    "Of all the things I've lost, I miss my mind the most" Click here to enlarge

    Sometimes it takes a full tank of gas before you can think straight.Click here to enlarge

    2010 Ultra Classic - Flame Blue pearl & Brilliant Silver Pearl

  7. #7
    New Member Liaison Tom's Avatar

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    What muffs you runnin-.',
    May I be "the least in the household of God."...

  8. #8
    Click here to enlarge Originally Posted by ultrat Click here to enlarge
    What muffs you runnin-.',
    Tom, I've got the factory housings with a Fullsac 2" re-core kit installed.
    Wayne
    Past Master 1995
    Old Fort Lodge 420
    Summerville, SC

    "Of all the things I've lost, I miss my mind the most" Click here to enlarge

    Sometimes it takes a full tank of gas before you can think straight.Click here to enlarge

    2010 Ultra Classic - Flame Blue pearl & Brilliant Silver Pearl

  9. #9
    New Member Liaison Tom's Avatar

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    Are those like American custom .. looks stock on outside different inside?? ,'.,,
    May I be "the least in the household of God."...

  10. #10
    Yeah, and they have a different end cap too. I got the slash downs
    Wayne
    Past Master 1995
    Old Fort Lodge 420
    Summerville, SC

    "Of all the things I've lost, I miss my mind the most" Click here to enlarge

    Sometimes it takes a full tank of gas before you can think straight.Click here to enlarge

    2010 Ultra Classic - Flame Blue pearl & Brilliant Silver Pearl

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