Well I needed another cat for my Sidekick as the stockie was falling apart, I searched around and found a Magnaflow replacement cat for 126$ http://www.carpartswholesale.com/v5/details/Suzuki/Sidekick/Magnaflow/Catalytic_Converter/1998/JX/4_Cyl_1-dot-6L/M6622626.html/?sc=Product+Listing+Page:4  here is a picture showing the new and old cat side by side.


The new Magnaflow cat is smaller, but has a high flow catalyst and is a 2.25" inlet and 2" outlet vrs the stockies 1 3/4" outlet. You can defenitely hear a louder, throatier exhaust tone, but not obnoxious at all with a stockish replacement exhaust. It should last fine as it is entirely stainless from flange to flange.

You think this would bolt up to a header?

Yes, bolts up just like a stock cat does. I have an ExtremeZuk SS header and this cat bolted up fine to it, you will need to get or fabricate a new gasket to connect up to the muffler section.

Sweet  thanks for the info I am in the need for a new exhaust system.

I am looking at a 2" mandrel bent rear section and use it with a Dynomax super turbo muffler(2" inlet/outlet).

Are you running a turbo?
I am running twin Cherry Bomb Trubo 2 1/4" mufflers on my 2.7L w/pre-cats, and they are very noisy when opening the throttle.  I am watching for something more mello.

The Dynomax super turbo is their quietest muffler, far quieter than the CherryBombs.

I have access to a 2" die , could probably bend one up . my own dies only go up to 1 3/4.

I have that CAT on my Tracker along with a 2" Magnaflow muffler and a complete 2" mandrel pipe exiting straight out the back for maximum clearance. I have bent my original exhaust tailpipe twice so I did not want a side exhuast behind the wheel.  I found that in big rocks if I catch the CAT the mounts would easlily slide out of the rubber mounts on the CAT. If you look at the first picture the original cat has expanded ends to prevent the mount from sliding off but the Magnaflow CAT does not.   I fixed that with threading the mount shafts with 1/2-13 threads and then put a nylon lock nut on the shafts.  No more of the CAT pulling the flex joint apart and making a racket.

I noticed the ease at which they can come off the hangars, I was thinking of drilling a hole for a cotter pin and a washer, but your route sounds a bit stouter.

Where did you snag those wheel well flairs?

I imported them from England