Header Honeycomb Removal - ZX6R Forum
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post #1 of 23 Old 10-08-2010, 09:54 AM Thread Starter
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Header Honeycomb Removal

Has anyone removed the honeycomb inside their stock header? Would it be the same process as removing the honeycomb from a car cat? Beat the bejesus out of it, busting it up into pieces and powder. I have an 09 that I'm looking to dive into. I'm not sure if the other year models have this?

Last edited by endeavor; 10-08-2010 at 10:04 AM.
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post #2 of 23 Old 10-08-2010, 12:19 PM
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get a cat back.remove cat and weld tube in then u still have cat for mot or rego what ever u call it.

dyslexia and adhd dont make for good spelling or gramer
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post #3 of 23 Old 10-08-2010, 06:12 PM
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There are three ways to get rid of it:
1) smash it out of the stock header.
2) cut it out of the stock header, and weld in a patch piece to replace the section of pipe that you just removed.
3) buy an aftermarket exhaust system.

Setp one: Obtain 5-8 squares of clean, dry toilet paper.
Setp two: some prefer to neatly fold while others prefer the "wad" technique, but you need to condense the squares into a thicker unit of TP.

...do I really need to continue?
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post #4 of 23 Old 10-08-2010, 07:33 PM Thread Starter
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I ended up just drilling and busting it out of the header. Took about 2 hours to do start to finish. Now to get the PC-V tuned.
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post #5 of 23 Old 10-08-2010, 09:50 PM
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probably would be quicker to cut it out and weld a new section eh?
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post #6 of 23 Old 10-09-2010, 12:27 AM Thread Starter
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Originally Posted by Gn6hami View Post
probably would be quicker to cut it out and weld a new section eh?
I wouldn't think so. If I were going to cut/weld, I would remove the header. I did everything with the header still in place.
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post #7 of 23 Old 10-09-2010, 03:10 AM
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How much crap comes out?

tinted screen, hel lines,intergrated tail light, rearset adjusters, K&N air filter, +4 advancer, -1 front, pazzo knock offs, ape cct, zip tie mod,07 shock + rear disk, 08 swingarm, vernhil rear line, 636 exhaust with dan moto cf can, Kleen air mod..

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post #8 of 23 Old 10-09-2010, 09:01 AM Thread Starter
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There was 2 honeycombs. Both were the diameter of the pipe(obviously lol) and about 2 inches deep. So I would guess it was a bit under 1 cup of powder and pieces.
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post #9 of 23 Old 10-09-2010, 02:04 PM
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Make any sound difference?

tinted screen, hel lines,intergrated tail light, rearset adjusters, K&N air filter, +4 advancer, -1 front, pazzo knock offs, ape cct, zip tie mod,07 shock + rear disk, 08 swingarm, vernhil rear line, 636 exhaust with dan moto cf can, Kleen air mod..

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post #10 of 23 Old 10-09-2010, 10:01 PM Thread Starter
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Make any sound difference?
Not that I can really notice. Although as I was expecting, there is now an occasional "pop" when decelerating. Much like what happened before I did the Kleen mod. No big deal, I have to get my PC-V tuned anyway.
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post #11 of 23 Old 10-09-2010, 11:26 PM
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you cant weld a patch or a section to the header unless u got lots of cash to blow. the header is made of titanium. you need a special environment to weld titanium. its not cheap. pinebox and i thought of it already and between the two of us together cant afford it. ive removed the cats from the header by drilling the center and using a chisle to remove the rest. works great. if u dont have a muffler on the end and u use a strait pipe then its alot louder and throws flames on decel. looks cool in pictures. performance wise its a good bit of difference over the stock setup. the PC-V will need to be tuned for sure.
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post #12 of 23 Old 10-10-2010, 12:43 AM
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you cant weld a patch or a section to the header unless u got lots of cash to blow. the header is made of titanium. you need a special environment to weld titanium. its not cheap.
Before the site when down, there was an excellend write-up by a member on here (cant for the life of me remember their user id) about doing custom exhaust. 05-06 model I believe. He made the exhaust similar to the buel 1125cr. The pictures showed where he cut the cat right out of the headers, then welded another short section of pipe where the cut was made. He also welded on a small muffler and tip on it. Anyways, besides it looking absolutely KILLER, I dont recall anything being mentioned about special accomodations.

Have you tried it before or? I actually plan on doing it myself. I already ordered and recieved the used headers to cut on. I wish that thread was still here for me to reference. My emissions are due in January, so Ill make sure I take pics when I attempt it.
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post #13 of 23 Old 10-10-2010, 04:20 AM
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G... it can be done if the header is made of something else. i remember the post ur talkin about too. he had aluminium headers and tail pipes. so welding that was a no brainer. if ur doing a titanium header tho theres alot to take into consideration. ive tried it before and it was too much moey to try as an experiment. if your doing it on ur bike and u dont have a titanium header then by all means do it up and post pics. in this post the original header in question was titanium and on a 09zx6r. same bike i own and race.
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post #14 of 23 Old 10-10-2010, 04:39 AM
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i thought that he had used a stock header from another year that was a direct fit, or very close to a direct fit. Not aftermarket or aluminum ones. I could be wrong though it was a while ago and my memory isnt that great. maaaan, i wish i knew how to weld... or kawifreak77 lived closer so he could hook me up. shits expensive. The thread youre talking about... did he use a carbon fiber muffler? thats the one im talking about.

Last edited by Gn6hami; 10-10-2010 at 04:41 AM.
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post #15 of 23 Old 10-10-2010, 04:42 AM
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i wish i knew how to weld... or kawifreak77 lived closer so he could hook me up. shits expensive. The thread youre talking about... did he use a carbon fiber muffler? thats the one im talking about.
it can be costly. yeah he did he also moddified it too.
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