A long flat blade screw driver works well to remove the cats, they are not difficult to remove. The biggest difference to the heat issue and freeing up the engine is the removal of the "solid" baffle and free flowing air filter, the noise increase is also not too dramatic. I think the best advice is to remove that baffle first, drive and then decide if you want to remove the rear baffle, drive again and if you want remove the middle baffle. In my case I removed the front baffle then drove for a season, then decided to remove the rear baffle, great performance lovely noise no heat and cost $60. Yes, use the drill to remove the baffles do not attempt to knock them out.
I had two front baffles and two rear baffles.
Put a small amount of never seize on the pipe connections to make it easier to remove and replace.
Your exhaust was probably an exception as there have been no other reports of more than 3 baffles in each pipe.
Hogzilla,
If you are going to drill out the baffles then this guide can help:
My recommendation is to remove the guide drill bit from the drill head, use lubricant such as cutter fluid or WD40 don't use the hammer drill but start the drill slowly without too much pressure this gets into the stainless steel and then speed up.
Last edited by britmog; 30/10/2007:19 PM.
Bruce 1964 4/4 Series V Comp (Megan) 1994 +8 (Maurice) tis no more 2013 M3W (Olga)
