Replacing pre-cat and downpipe with custom piece

graldo

Member
After many hours of reading on this forum, it seems to me that all can agree that the pre-cat and downpipe combination on the Protege is a serious exhaust bottleneck. While there has been much discussion about headers, I was wondering if anyone has just removed the pre-cat and downpipe and replaced it with a custom piece? (Not to be confused with a test pipe that replaces the secondary cat.)

In one thread about making hp/torque gains going n/a, a guy mentioned a custom downpipe made by Wagner Motorsports. I believe this was specifically for turbos -- it had a 2.5" diameter and came with a hi-flow pre-cat. However, I assume someone could make one with 2.25" diameter piping and no pre-cat for n/a applications. I wonder what kind of gains could be made with that? I imagine it would be pretty cheap to fabricate. Why not just eliminate that and save some $$$ instead of buying a header?

Also, if you had this fabricated and combined it with a Magnaflow ss cat-back 2.25" exhaust (list price $444.00 USD), you would be pretty close (ok, maybe a bit over) to the cost of the AWR header. Doing this would pretty much give you a straight 2.25" pipe from exhaust manifold to muffler -- no bottle necks and enough back pressure to maintain torque!

The bonus to me with this system is that to pass inspection (for those who have to), all you would need to do is put the stock pre-cat and downpipe back in place. Of couse you'd have to take care of the CEL when running the custom downpipe, but there is more than enough info on how to do that.

I'd really like to hear some opinions on this setup and what kind of gains to expect -- particularly if someone has actually done it (I'd just be happy to know what the SOP test says, but a dyno chart would be nice). Torque is more important to me than hp becuase I mostly do city driving and only want to be able to zip through traffic. I have also attached a picture of the Wagner downpipe.

Thanks.
 

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There was a guy that had modified his cat/downpipe. Try a search for traveller. The cat/downpipe you are mentioning is for N/A cars-or at least wagner makes it for both n/a and turbo cars..
Traveller had some dyno results..
 
Thanks for the reply, Mike. I looked for Traveler (he dropped an "L" ;-) ), but most of his posts deal with a custom "shorty" header he designed. It seems to me he never replaced the stock pre-cat and downpipe. However, he did mention gutting the pre-cat but that still left him with the downpipe bottleneck.
 
Ok, I see what you mean. The gutting the cat part I took from another thread on here after doing a search for Traveler's posts. The problem I see with his system is the 2.5" custom cat-back exhaust he put on there. From what I have read on here (and elsewhere), that going above 2.25" with an n/a engine causes you to lose back pressure, thus more importantly (for me anyway) torque. It is interesting to note that even with all those additions (cam, custom header, larger cat outlet, etc), he only gained 15 hp and 12 lbs of torque. With the AWR header you gain 11 hp and 11 lbs of torque. According to other posts regarding the Magnaflow cat-back, you gain 8 hp and 10 lbs of torque. Total = 19 hp and 21 lbs of torque. (The figures might be fudged a bit).

I figure with the setup I am proposing you could gain approx 13 hp and 15 lbs of torque -- that is giving 5 hp and 5 lbs of torque to the custom downpipe (could be more) and the rest to the cat-back. I know, I know, people will say do it and dyno it then make your fancy predictions! I guess my point right now is to research and decide if it's worth doing. On the other hand, just getting the header with no cat-back mods might be a better way to go.
 
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Yeah, I remember that. I actually posted in there about the wagner dp. Wish it was less expensive.
 
Yes, it was something riddiculous like $400...but it was stainless steel and included a cat. However, I'd bet you could make something similar out of mild steel for about $200 or less (depending if you have a friend who can weld) without the cat.
 
Apparently the cat he uses on that beast costs $300 itself, and due to the limited space, he's pretty much restricted to using that one, as far as from Random Technology. I was going to use a cat from Magnaflow for my setup, and an elbow; Literally, though, there's about 12" of pipe between the flange outlet of the manifold (Or the shorty header in my case), and the area it has to be bending. So, we're pretty limited, there. The body of the Magnaflow that I'm going to use is 9", which leaves me with not much room, plus having to trim the top and bottom to make it fit. Whee!
 
hollow cat

i just hollowed my pre-cat.. does the trick and i can swap it easy. But i will eventually get a header and add a hi-flow cat downstream + new 02 bung for emissions. ultimately u will end up spending as much as a new header on the custom fab.
 
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I dunno... The cat I'm getting is about $70, and the pipe bend is $14. =) The welding is done myself, the O2 bung is $2.50, and the flange at the back cost me $3, and I made the header flange for free out of 1/4" flat stock metal. =)
 
Not at all! Catalysts are good. =) Keep you road legal, and the air nice and clean. Hehee. Seriously, though, the cats aren't so much the restriction as the pipe that narrows to a mere 1.2" that comes right off of the catalyst. The cat itself is rather decent flowing, from what I gather, and the Magnaflow is probably just as good, and Random Tech is probably better by a good margin.

And if I were going to eliminate the cat, I'd just get a 90 degree bend, and call it a day! =)
 
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