How To Gut a Cat
I decided to remove the catalytic converter and clean it out. Yes, I know it is used to reduce emissions. Talk to China first. While it was out I did several measurements of it. Making a few x-pipes for some friends that want them.
Pretty simple process. Simply remove it, cur it open at the cross welds. Remove the element and weld it back together. Ensuring you have the same distance as you measured before cutting. This distance can be varied by a mm or so and you're still good because the header and muffler outlet can move slightly.
The weight removed here is significant as most of the weight is from the element inside and not the outer stainless steel shell.
The sound? Identical to an x-pipe as compared to my friend who has one installed. Yes, it does have a more "mechanical" sound out the exhaust and a very slight increase midrange 2000-3500 rpm. Not bad for a few hours. And not $300.