Question: How to Hollow Out a Catalytic Converter: Step By Step

Keeping the catalytic converter in good working condition is essential for the car and your health. This component in the exhaust system converts pollutants into environmentally friendly compounds. A functional catalytic converter will purify over 90% of contaminants in the exhaust.

Unfortunately, catalytic converters clog over time, leading to engine performance issues. One way to fix a clogged converter is by hollowing it out. Some vehicle owners will hollow them out to save on replacement costs.

If you’re determined to hollow out your converter, this article has you covered. I’ll provide detailed steps on how to hollow out catalytic converter. You’ll also learn the consequences of hollowing out this device.

Question: Is It Safe to Hollow Out a Catalytic Converter?

Hollowing out catalytic converters can hurt the environment and your health. A hollowed-out converter will no longer reduce the emission of pollutants into the environment, leading to health risks. This activity can also hurt the engine’s performance.

Tampering with the catalytic converter has legal repercussions in most states. Hollowing it out might land you in legal trouble after failing to follow the legal guidelines.

Before considering this task, seek better solutions to keep the converter in good shape. You may clean it by soaking it in soapy water to remove clogs. If the clogs don’t come out, consider replacing your old converter.

However, if you must hollow it out, there are ways to complete this project.

Answer: How to Hollow Out Catalytic Converter

You can hollow out your catalytic converter by removing it from under your vehicle. Alternatively, you may hollow it out without removing it from your car. Read on to understand the two methods of hollowing out this component.

How to Hollow Out a Catalytic Converter by Removing It

Here’s how to hollow out the converter after removing it.

Step 1: Gather the Necessary Tools

You’ll need tools like a wrench for screwing bolts and two-floor jacks for lifting your car off the ground. Respiratory protective equipment will also come in handy to ensure you don’t inhale pollutants in the converter. You’ll also need a crowbar and a hammer to remove your converter.

Step 2: Put on the Respiratory Protective Equipment

The catalytic converter is part of the exhaust system, so you expect it to have a buildup of dust and harmful pollutants. So, start by putting on your respiratory protection before beginning the work. Ensure your working area has adequate ventilation and access to water.

Step 3: Jack Up Your Car

Lifting the car with the two-floor jacks will help you to access the converter easily. You must ensure the ground on which you place the two jacks is firm. A concrete driveway or your garage can prevent the jacks from falling off.

Step 4: Remove the Catalytic Converter

First, locate this component under the car, attached to the exhaust. Use your wrench to loosen the bolts securing the converter to the exhaust. Then, detach it from the exhaust.

Step 5: Hollow It Out

Place the converter on the ground, position it upward, and secure it with clamps. Then, place your crowbar on the converter’s honeycomb core. Hit the crowbar with your hammer or mallet, and do this gently.

The goal is to remove the honeycomb core or break it into smaller pieces that are easier to remove.

Step 6: Reinstall the Hollowed-Out Converter

Place the hollowed-out converter into its original position attached to the exhaust. Reinstall the bolts and use the wrench to tighten them. Remove the two jacks and test-drive your car.

Answer: How to Hollow Out a Catalytic Converter Without Removing It

These steps will help you hollow out the converter without removing it from your car.

Step 1: Gather the Tools Needed

Hollowing out a catalytic converter is a tricky process and requires several tools. Below are the necessary tools you’ll need for the project:

  • Grinding wheel
  • High-lift jack
  • Crowbar
  • Hammer
  • Chisel
  • Nose pliers
  • Cold weld epoxy
  • Protective gear (hand gloves and fireproof goggles)

Step 2: Lift the Car

Use a high-lift jack to lift your car from the ground. You can also use a pneumatic lift for this job. The goal is to access the converter under the car effortlessly.

Step 3: Put On the Protective Gear

Wear your hand gloves and welding goggles to protect your hands and eyes from burns or flying particles.

Step 4: Create a Flap

Locate the converter and use your grinding wheel to make three right-angled cuts. The cuts should be at the base of your converter. Give the converter a few minutes to cool down. Then, use your crowbar to bend the flap downwards.

Step 5: Break Apart the Converter’s Ceramic Lining

Chip away the ceramic lining in your converter using a hammer and a chisel. The ceramic lining resembles a honeycomb and will break apart with gentle taps of your hammer and chisel. You must remove all the ceramic pieces from the converter.

Step 6: Close the Flap

Use the nose pliers to bend the flap back into place. You’ll need more force to bend and close the flap. Then, use the welding machine to join the flap. Doing so protects the converter from a leakage problem.

Step 7: Check for Leakage

Test-drive your car and listen to the sound your exhaust makes. If you hear a hissing noise or rattles, there’s a leakage from the converter. Use cold weld epoxy to seal leaking parts.

Answer: Pros & Cons of Hollowing a Catalytic Converter

You now know how to hollow out catalytic converter in two ways. But what are the consequences of hollowing out this component? Here are the benefits and drawbacks of hollowing out converters:

Pros

  • It’s cheaper: Replacing a malfunctioning or damaged catalytic converter can be expensive. The average cost of replacing this component ranges between $950 and $2500. If you’re on a budget, you can hollow out the converter at home at a lower cost.
  • Reduced operating temperature: A catalytic converter traps exhaust heat and uses it to convert pollutants into less harmful compounds. The heat trapped in the exhaust can increase the engine operating temperature. Hollowing out the converter eliminates this heat, reducing operating temperature.
  • Better gas mileage: A catalytic converter will cause the engine to work extra hard to generate the heat required. The more your engine works, the more it consumes fuel. Hollowing out the converter results in better gas mileage.

Cons

  • Increased pollution: A Hollowed-out converter will increase pollution and cause health issues.
  • Legal repercussions: Many states consider hollowing out converters illegal. If you tamper with your catalytic converter, you risk getting fined or imprisoned.
  • Reduced power and torque: A hollowed-out converter can produce low power and torque. Lack of back pressure may hurt your engine over time, leading to performance issues. You’ll notice a significant decline in power and torque.
  • Warranty issues: Hollowing out the converter can void your car’s warranty. In the case of engine or exhaust system damage, you may end up with expensive repairs.
  • More Noise: A hollowed-out catalytic converter can cause loud noises while driving. Sometimes, this noise may go above 100 decibels, way higher than the safe noise level.
how to hollow out a catalytic converter without removing it

Wrapping Up

You can hollow out catalytic converter by removing it from your car or not. Whichever method you choose, ensure you have the necessary tools to do the job.

If you’re eco-conscious, you should look for alternative ways to hollow out a catalytic converter. This component reduces emissions by converting harmful pollutants into environmentally friendly products. You should also note that hollowing out your converter has legal repercussions and may harm your engine.

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