hi

got some short extractors like in this link http://www.ebay.com.au/itm/FORD-6-CYLIN ... 2c67a800ec and wondered wether the std cat converter and the pipes attached are ok.

is there any way to make them be able to bolt straight onto the old cat converter and pipe like cutting the pipe back on the manifold end of the cat converter and welding the same flange as the extractors on.

is it possible to modify the extractors to be able to weld a 2 bolt flange

modify the exhaust not the extractors.

cutting the pipe on the engine side of the car and putting a new flange on to match the extractors is not hard if you know how to weld.

it won't take a muffler shop very long either.

any other ideas

The one that Thomas123 posted is the correct one. You can use the existing Cat, you just need to cut it down to size to suit. Where the factory cat bolts to the factory manifold is the pipe you cut down, just get a 3 bolt flange from an Exhaust Shop to suit, 2.5" by memory. also get a gasket. I did a set for Raven79 not long ago. Not hard if you can weld, if not take it too an Exhaust Shop and have them fit them.

you answered your own question. cut the pipe, add any bits to make it fit evenly, add the same flange as the extractors.

don't think about it too much, its a simple job.

whats the time frame for fitting the extractors and cat together as one

All comes down to who is doing it. Workshop would be 1 to 2 hrs, with your mates, could take all day

how do you minimise time fitting them

by hurrying up...
would you like us to fit them for you..

it should only take about 30min to weld i did and ive never welded in my life

then once its all in one piece about 20mins to fit on the head and anther 15 to get under and do it up to the cat back

oh and make sure you test fit it all in the car then tack weld it so you dont go to all the effort of welding and end up with it not fitting at all

This is what you needs to be done

Parts
1) Exhaust Manifold gasket
2) 2.25" gasket to suit the flange after the Cat section (engine pipe).
3) Some exhaust Jointing Compound

I would also recommend getting some M10 Cap Screws for the extractors to the head (Allen Head Bolts) I find these much easier to fit and tighten, but that is optional.

Process
1) Raise the car and put it on stands.
2) Remove the rear section of the exhaust from the Cat section (engine pipe). 2 Bolts
3) remove the heatshield from the existing exhaust
4) Remove the O2 sensor
5) Spray the Exhaust Manifold bolts with some WD40 or such (Optional)
6) Remove the 2 nuts from where the Cat section (engine Pipe) the studs may come out but who cares. either way works.
7) Remove the 2 bolts holding the engine pipe to the exhaust hanger off the gearbox mount.
8) bPull the engine pipe out from under the car
9) Loosen and remove the exhaust manifold bolts
10) Lift out the exhaust manifold.
11) Bolt the new 3 bolt flange to the extractors. no need to use gasket.
12) Fit the extractors through the engine bay using the new manifold gasket. If using the old bolts, they may need to be shortened due to the extrator flange being thinner than the factory manifold. You should be able to fit these without removing the sterring shaft.
13) Cut the engine pipe down to suit the length needed to fit to the extractors with the new flange bolted to it. You may need to trial fit this a few time till you get it right. take your time and don't rush it.
14) when you have the cat pipe right, disconnect the battery and then tack weld the cat pipe to the flange bolted to the extractors. You will need to do this from under the car of course.
15) When tacked, remove the extractor flange bolts and remove the Engine Pipe.
16) Fully weld the pipe to the flange.
17) Cool the pipe and then refit to the car tightening all the bolts.
18) refit O2 Sensor
19) Reconnect the battery
20) start the car and check for exhaust leaks
21) If all is good, lower the car to the ground and you are away.
22) Check all your bolts after a few hours of driving to ensure they are tight.

All complete

Last edited by SWC on Sun Aug 26, 2012 8:13 pm, edited 1 time in total.

nice how to should be in the tech documents

while on the subject i may need to put a 2nd or 3rd gasket in between where the cat back and cat joins up due to i kind of misjudged by a 3-4MM

will the standard exhaust pipe diameter be ok on the cat converter for the extractors if it was just cut back a bit and when getting a 3 bolt flange would you still get a 2.5 in diameter for the 2 1/4 in cat converter pipe or just get the right diameter flange for the pipe

reuse your cat pipe that flange

Engine side the Cat is 2.5". Rear of the cat is 2.25". As I said get a 3 bolt 2.5" flange and gasket to suit to bolt to the Extractors. This matches the flange on the extractors.

2.5" is the right size