Catalytic Converter Recycling: Replacement Pipes

Hi,
Since our return trip from vacation this weekend, our car has been exhibiting the following problem:
When starting (fully loaded plus with a Klaufix device), there's a clunking noise coming from the exhaust.
This effect does not occur when the vehicle is unloaded (although it is still somewhat noticeable). When loaded, the vehicle also sits lower than it used to.
I suspect (I haven't had time to put it on a lift yet) that the exhaust pipe is cracked near the catalytic converter (it already looked quite corroded), and that the entire exhaust system is shifting so much when the car is loaded that it could make mechanical contact. Furthermore, the rear shock absorbers will likely need to be replaced sooner or later.
Michael II once wrote something about a 'dislodged monolith' in the catalytic converter, which could explain some unusual noises.
Since a new catalytic converter costs about 330 EUR, I'm wondering if it's possible to recycle the (cleaned) monolith by incorporating it into a replacement catalytic converter pipe.

- Has anyone ever tried something like this before?
- Where can one find decent replacement exhaust pipes for KAT (catalytic converter) systems?
- How much do they cost (is it even worth the effort)?

Hello Rudi,

Here comes the funny part:

Upon my return from vacation (last Friday), I also noticed strange rattling noises coming from the exhaust area! It turned out that only the muffler had detached from the exhaust system, and the best part was that the engine wasn't significantly louder without the muffler.
Shake the end of the tube to see if it feels loose.

Hello Bertil,
The exhaust pipe was due for replacement back in February .
I hope to be able to come and watch the game this weekend.

Hi,
If you replace the catalytic converter with a pipe, make sure to install a silencer in between instead of connecting it directly to the exhaust pipe. Otherwise, you will lose power because you will be missing some back pressure.

For example, go from a diameter of 60mm to approximately 50mm, then back to 60mm, and it should work.


Good luck.

Hello Tim,
The idea with the pipe isn't bad, but (unfortunately) it's illegal .
I was thinking about getting a cat, but I don't want to spend over 300 EUR. A cat simulator would probably cost somewhere between 50 and 100 EUR (I haven't found anything specific for TDi's yet).
Then cut it open, remove the contents, insert the old monolith, and weld it back together.

Hello Rudi,

I drive past a company every morning here in Nuremberg that installs/sells aftermarket/replacement catalytic converters. I'll go check it out during my lunch break.

Best regards, Rainer.

Great!

'Thank you very much!'

Hello Rudi,

The company is only a Bosch service center that retrofits catalytic converters.
The company sells KATs, among other products, from the company GAT http://www.gat-kat.de/.
According to their expert, there are different G3 variants with a 1Z configuration, each featuring a different bracket.
On the GAT company website, there is one catalytic converter available for the G3 Variant 1Z model, priced at 280 euros plus VAT.

Best regards, Rainer.

Hmph...

That's almost the same price level as VAG.

Nevertheless, thank you very much for your effort.

Just do it like I did... Eventually, I knocked out all the junk that was stuck in the catalytic converter using a hammer and chisel. Then, it was game over. Once I got it to rev up, all the debris came flying out. LOL.

Since then, I've been driving around with a completely empty catalytic converter! But be careful... it makes a terrible noise!

I should also mention that my catalytic converter was loose and was constantly clogging the exhaust, which is why I took that action.

cu

chris

Question for Mtw13ve: Does the car now really produce a lot of exhaust smoke without a catalytic converter?

And what about power consumption, performance, and noise levels?