I started of by disconnecting the exhaust clamps. One where the front pipe meets the manifold and the other where the front pipe meets the centre section. The Haynes Manual suggests that after loosening these clamps the front section should easily slide out of the back section. This is not the case. I had to remove the front section mounting and batter away with a hammer for a good few minutes to get them separated. To my despair this is what I was left with.
As you can see from the pic’s my exhaust was done and had holes in several places. At this point I should have scrapped it and looked for a replacement from a breakers yard but I decided to have a go at mending it and continued on. I was able to buy a flexible piece, some flexible tubing and a new clamp from my local motor factors for £29.
I started off by cutting off the flange and welding it to the new flexible piece. Next I had a go at patching the area around the mount. I did this by cutting and flattening two pieces of the new pipe so I had good metal to attempt the patches either side of the mount bracket. Next I removed the CAT section and welded in the new piece of pipe, I cut a slit at either end of the new pipe so I could flatten it and slide it inside the original exhaust making it easier to weld and stronger too.
Now with everything welded I attached the new flexible section to the manifold. Knowing how difficult the exhaust was to get off as one section, I kept the flexible downpipe piece separate from the straight pipe. With the flexible piece secured, I was able to slide the straight pipe into this and secure it with a clamp. It also made it easier for me to get it slid back inside the middle section. With it all secured I sealed the joints with some exhaust gum and tightened the clamps. Job done!
Video of exhaust note: http://www.youtube.com/watch?v=NDSYEhEZ2m0
First impressions: It’s a great little mod, I de-cated my 106 and was impressed and I’m even more impressed with the results on the 406. What I’ve noticed is a more responsive, freer revving engine. Acceleration in 3rd and 4th gear is now much improved and there’s a lot more urgency when you press the accelerator. Also there isn't a really an increase in noise inside the cabin, maybe more turbo whistle and you can hear a beefer note from the exhaust when standing behind the car. Hope this has cleared up some of the de-cat questions that often come up and hope you’ve enjoyed reading it.
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bugger i reckon im sh1t outta luck with that one too.
) I did ask about leaving it out but they said the tried it and the car was as flat as a pancake.
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