Cat Bypass

[red911]

Need to know if there is a trick to installing a cat bypass. I just purchased one that was never used, from a Pelican Member. I removed the Cat and everything went well. I tried to bolt up the bypass pipe to the muffler flange. It does not line up . It looks like the muffler has to move toward the fender so it will seat correctly. When I mount to the muffler flange first it does not line up with the exchanger flange. Do I need to loosen the muffler clamps to get enough movement from the muffler to line this up correctly? I did have up and down movement from the muffler but no side to side and that is where I need it. It is a stock exhaust on a 1983 911SC Targa. Any help would be greatly appreciated.

Thanks,

[911nut]

If you have an acetylene torch you can make the pipe move in the direction that you need (I had the same problem with the PP cat bypass pipe).
Here's how to do it: Install the pipe. Don't connect it to the muffler. Take the torch and heat the pipe just forward of where the 6 manifold pipes meet the 2.5 inch pipe. Heat the side in the direction in which you want it to move (for me it was the outboard side, toward the left rear wheel). Heat it until it's bright red, from the top of the pipe to the bottom of the pipe. Take the torch off and immediately spray it with cold water (while it's still red hot). This will distort the pipe in the direction that you need it to go (welders call this "flame straightening").
If you need more movement you will have to have a muffler shop bend it for you.
Good luck.

[GB83SC]

On my 83SC it bolted right up to the stock muffler, there is no movement on my muffler. Sounds like loosen the straps a bit then it should give you the right angle to bolt up. I will be removing my stock muffler this weekend and replacing it with a GHL single in dual out, cant wait to hear some noise.

[Kurt B]

Like George says, loosen the muffler straps and move it forward. In fact, grab a jack, put the jack under the muffler to hold it up (so it stays straight and in place)and you can move it into position.

[Rick Lee]

I just removed my cat to get to my left lower valve covers and it was a miserable experience. We replaced the exhaust bolts and gaskets. Since a test pipe is going on after my next emissions inspection, I'm wondering if I need to replace the gaskets again - it will only have been about 2 mos. But are they reusable?

[GB83SC]

Richard,
When I installed my cat pipe I ordered new gaskets, It took a blow torch to get the old bolts out so I know that they have been there for many years could be the originals, and to my surprise the gaskets where in one piece and I reused them. I would think your fine to reuse yours.