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[TheBoy]

The exhaust steel is mega hard due to the heat cycling it gets!

Step cutter wont do it, a good hole saw is the only reliable way and consider it disposable once complete!

I have done a few now, including a conversion on a 3.0 set for fitting to a 3.2......

Indeed, it wrecks hole cutters.

Wonder if you can get diamond tipped hole cutters?

[tigers_gonads]

The exhaust steel is mega hard due to the heat cycling it gets!

Step cutter wont do it, a good hole saw is the only reliable way and consider it disposable once complete!

I have done a few now, including a conversion on a 3.0 set for fitting to a 3.2......

Indeed, it wrecks hole cutters.

Wonder if you can get diamond tipped hole cutters?

Yup 
Not cheap 
http://drillbitwarehouse.com/index.php?page=shop.product_details&flypage=shop.flypage&product_id=759&category_id=47&vmcchk=1&option=com_virtuemart&Itemid=600001

[Kevin Wood]

Aaron has a pit. Kevin can weld, I think? And he needs his done too. Can these be done with cats in place...?

Sounds like a good plan for a pre-curry bit of mechanic-ing to me.

I suspect we need to have a plan for drilling out and replacing multiple cat-to-mid-section bolts while we're at it. Worth getting in some decent bolts and drill bits in advance.

I also know for a fact that one of my lambdas is "reluctant" to come out of the exhaust.

I've also been meaning (as has Kevin) to try "O2 spacers" and see if that works, as that requires no welding.. but we've both been slack (unless Kevin's tried it since we last talked about it, anyway).

Yes, I tried it and failed at the first hurdle. Nose of the O2 sensor was too fat to fit inside the spacer.

I think the tried and tested relocation is the best option.

[Brikhead]

The exhaust steel is mega hard due to the heat cycling it gets!

I think it's stainless which is harder than mild steel anyway, that said I managed to get through it with a regular 'Irwin' hacksaw blade quite easily, until I ran out of space under the car.

Can the work be done when the cat section is attached to the car or does it need to come off?

Id say it would be impossible to re-site the lambda's with the down pipes still on the vehicle, you'd also need to mark the new position before you removed the pipes as there isn't much clearance for them after the main cat...

[Brikhead]

...you'd also need to mark the new position before you removed the pipes as there isn't much clearance for them after the main cat...

Before the main cat, that should be!

[feeutfo]

The exhaust steel is mega hard due to the heat cycling it gets!

Step cutter wont do it, a good hole saw is the only reliable way and consider it disposable once complete!

I have done a few now, including a conversion on a 3.0 set for fitting to a 3.2......

plasma cutter...? Or would it cut through both sides? ...and if so, who was it that had one?  ...oh for a memory.

[aaronjb]

Mr 2woody has a plasma cutter - not sure you'd make a neat enough hole, though.. maybe with practice, but who wants wobbly leaky holes in their exhaust?

[feeutfo]

Mr 2woody has a plasma cutter - not sure you'd make a neat enough hole, though.. maybe with practice, but who wants wobbly leaky holes in their exhaust?

Depends how good Kevs welding is... I reckon I could get it pretty close. Start in the middle and work out. Easy sitting here though.