gutting headers

[oh whell]

Anyone knows how to gut the stock pipes and baffles on 6th gen bike.
I am able going to get the staintunes
but if I can bypass spending the $500.00 for the motad headers I would
does anyone know of a post with pix they really help.
It looks easy to do just cut off where the cat is right????
And fab a new pipe (know someone at a muffler shop)
I’m a little concerned about the pipes do not cross on the motad and they do on the stock.
i would think no difference because they all collect to one any way (should I be concerned)

OK IT'S DONE

It's done gutted the cat () this was not easy about 1.5 hours
but the gutts are out take a look lots of pics.

1. Need a friend with a plasma torch (and knows how to use it)
2. knowing where to cut is have the battle
3. after 50 mins figured out (melt the HELL out of it)
4. do one cone and the other will fall out
5. weld a piece of medal back over hole
6. done


ok but now need the .99 cent O2's
1. radio shack 1/4 watt 330 Ohm 5% tolerance (really .99)
2. find your o2's follow the wire back to a black and green colored connectors
3. remove your o2's the connector to you bike on the opposite side of the lock clip of the connector (pix)
4. heat sink them or elec tape (to keep water out a lite coat of petroleum jelly will do great.
5. plug your o2 holes with bolts youcan get at any auto parts store
6. now buy your PCiii or PCv for your ride.

[dogman]

I'm just doing mine ATM.
I have just cut through the catalytic converter box just behind the cat, then I drilled/chiselled the guts out of the cat, and now am waiting for a guy to reweld it.
I thought about cutting it at the front and putting in a new pipe with a Y join but it is critical to get the alignment of the exit pipe correct, and didnt want to stuff it up.

[oh whell]

Originally Posted by dogman

I'm just doing mine ATM.
I have just cut through the catalytic converter box just behind the cat, then I drilled/chiselled the guts out of the cat, and now am waiting for a guy to reweld it.
I thought about cutting it at the front and putting in a new pipe with a Y join but it is critical to get the alignment of the exit pipe correct, and didnt want to stuff it up.

Got any pix of what you have did?

[Meatloaf]

There are two ways that you can get rid of the cat and still use the stock headers. First is to cut the bottom half of the cat out, remove the catalyst inside, then weld the bottom part of the cat back on. This is the easiest to do as you never truly seperate the front and back of the headers and have alignment issues. However it is also less preferred as it creates an open area for air to swirl around in, create turbulance, and thus theoretically not giving optimal performance.

Second is to cut behind the cat, in front of the cat, and weld in a straight pipe. This is more optimal as there is no room for the air to get stuck in and swirl around... but introduces alignment issues if not welded correctly.

There is another option to the headers here that you haven't mentioned. You can in fact mount up a set of headers from a 98-99 VFR. The headers are slighly larger in diameter than those on the 6th gen (45mm vs 43mm), bolt right up without modification, and have no cat or O2 holes, The crossover on these pipes are different and they are not stainless steel, but they can be had for around $200. Im not sure if they have the stop for the center stand on them or not, but I do know that mine have the stop hose clamped on in the correct place. Not sure if this was factory for that year or not.

I scored my set of 5th gen headers for about $180. I chose this route as an alternative to the Motads and Dekelvics so that I did not have to mod the stock. I also might be going with PC5 and weld in a hole for the auto tune sensor... Not something I would want to do to a brand new set of Motads.

Hope this information helps.

[Action]

Originally Posted by oh whell

I’m a little concerned about the pipes do not cross on the motad and they do on the stock. i would think no difference because they all collect to one any way (should I be concerned)

The stock pipes actually cross in front and in back. Like Meatloaf said their are other options. Stock 98/99 headers are a good option as long as you live in an that doesn't have a rust problem. Motad and Delkevicks both work well. I picked up the Delkevics for $275 shipped and they are stainless. They did take a little work to get the fit right.

Action

[dogman]

Originally Posted by oh whell

Got any pix of what you have did?

Here is a pic of the cat after I cut through the box. I am still waiting to get it back from the welder.
I have removed all the honeycomb material, which is tougher than it looks.

[kc7zrb]

how u do it, torch, with long chizle and sludge hammer? thats what i've used

[oh whell]

In the above post i knew a friend who has a plasma cutter
plus a arc welder i had a cutting torch my dad gave me. But you really need the Plasma touch for sure
(MELT, MELT, MELT, THE HELL OUT OF IT) Pay close attention on where to cut.
Just look where we cut it: look at and the gutted pix they show it well, plus look where it is attached.