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Thread: New Catalytic Converter Fabrication

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  1. #1
    Senior Member Azmodon's Avatar
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    New Catalytic Converter Fabrication

    Project #1 for this year

    When installing the cat-back I noticed some severe rusting happening to the lower half of the cat's flange, so much so that it's having trouble sealing (can see light through the entire lower half), and it bends out of place under the spring bolt's load. Tried fixing this temporarily with high heat epoxy but... here we are.

    From the flange mating face to the weld bead at the back of the cat is 12", and the post-cat O2 sensor is ~2" beyond that. So since the second cat on our cars isn't tested by the computer (and thus could be completely removed with no check-engine light issue, but wanting to at least look responsible for anyone who happens to peak underneath...) I picked up a Yonaka race cat (they're out of Ottawa but prices are USD with silly shipping). The issue is that the thing is 11.625" long, with 2.5" cone terminations:
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    The tube leading from Cat#1 to Cat#2 is 2.125"... because why would they pick a normal size for reducers and couplings... So a 2.125 ID to 2.75 reducer is on the way, as well as a 2.5 to 3.5 for the flange side. some cutting and welding later and I should have something that can slip on perfectly with room for a clamp.

    Digital before and after :P
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        __________________________________________

        click to view fuel log View my fuel log 2015 Micra SV automatic: 7.1 L/100 km ... 39.9 mpg (Imp) ... 14.1 km/L ... 33.3 mpg (US) ...


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  3. #2
    Administrator MetroMPG's Avatar
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    Subscribed for progress updates!

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        click to view fuel log View my fuel log 2015 Micra S manual: 5.0 L/100 km ... 56.5 mpg (Imp) ... 20.0 km/L ... 47.0 mpg (US) ...


  4. #3
    Senior Member Azmodon's Avatar
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    Shippment #1 has arrived, this is more so for the front swaybar brackets that are a year overdue, and the rear swaybar I'll be making

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    Fun side note, apparently the worlds having a bit of a helium shortage, so I have to wait for our supplier to get tri-mix in again before I can actually do any welding lol (unless... I wonder how much SSF-6 costs...)

        __________________________________________

        click to view fuel log View my fuel log 2015 Micra SV automatic: 7.1 L/100 km ... 39.9 mpg (Imp) ... 14.1 km/L ... 33.3 mpg (US) ...


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  6. #4
    Senior Member Azmodon's Avatar
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    Shipment 2 is in, cutting and welding time

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        __________________________________________

        click to view fuel log View my fuel log 2015 Micra SV automatic: 7.1 L/100 km ... 39.9 mpg (Imp) ... 14.1 km/L ... 33.3 mpg (US) ...


  7. #5
    Administrator MetroMPG's Avatar
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    You going to document the sway bar build too?

        __________________________________________

        click to view fuel log View my fuel log 2015 Micra S manual: 5.0 L/100 km ... 56.5 mpg (Imp) ... 20.0 km/L ... 47.0 mpg (US) ...


  8. #6
    Senior Member Azmodon's Avatar
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    Likely everything on my build list will have some type of write up and pictures. This spring it's the cat, front sway bar tabs, rear bar, side skirts. My phone's camera has been glitching out though so hopefully it plays nice.

        __________________________________________

        click to view fuel log View my fuel log 2015 Micra SV automatic: 7.1 L/100 km ... 39.9 mpg (Imp) ... 14.1 km/L ... 33.3 mpg (US) ...


  9. #7
    Senior Member Azmodon's Avatar
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    Who says you can't use a wood lathe and a hacksaw for stainless?

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    Bit of final prep tonight, using tig rod to centre / jig the cones just right, hopefully welding tomorrow night.

        __________________________________________

        click to view fuel log View my fuel log 2015 Micra SV automatic: 7.1 L/100 km ... 39.9 mpg (Imp) ... 14.1 km/L ... 33.3 mpg (US) ...


  10. #8
    Senior Member Azmodon's Avatar
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    So first we ran out of gas, then we got gas but the welder was booked, then we ran out of wire - Finally back in action.

    Since the cat's a bit more critical I "tested" the settings I'll need to avoid sugaring and slapped the swaybar tabs together, they just need to be cleaned up and should be able to get installed. I have no prep pictures on setting these up... they should be very straight forward.

    1.5" x 1/8th 304 = the two short pieces (the narrow one is just ripped in half)

    1.5" x 3/16 304 = the long piece and the tab

    lengths / angles etc. match the stock shocks placement * the tab's hole location is ~0.25" further out from the body than stock - I wanted to leave enough clearance to get passed the larger brim on the Tein's, but can be bent if it's really needed.

    Also, holy **** does 75/25 splatter like crazy... I miss helium so before I get flak for ****ty looking welds :P wrong gas + no back purge, so temp + speed has to be adjusted - nearly fouled up the backside of the 3/16 while attaching the tab.

    clean up sucked but I don't have pictures of that right now... finished at 4am last, this morning.

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    Last edited by Azmodon; 02-25-2019 at 04:48 PM.

        __________________________________________

        click to view fuel log View my fuel log 2015 Micra SV automatic: 7.1 L/100 km ... 39.9 mpg (Imp) ... 14.1 km/L ... 33.3 mpg (US) ...


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  12. #9
    Administrator MetroMPG's Avatar
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    I love welding. I've got a crappy wire-feed one, and an ancient stick welder. I weld something maybe once a year. My welds usually look like crap, but nothing has broken yet!

        __________________________________________

        click to view fuel log View my fuel log 2015 Micra S manual: 5.0 L/100 km ... 56.5 mpg (Imp) ... 20.0 km/L ... 47.0 mpg (US) ...


  13. #10
    Going right off the bolts instead of welding to the coil overs.. nicely done... wanna make another after test fitting?

        __________________________________________

        click to view fuel log View my fuel log 2015 Micra S manual: 7.7 L/100 km ... 36.8 mpg (Imp) ... 13.0 km/L ... 30.6 mpg (US) ...


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