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I purchased my 3" hi-flow cat from ProMuffler dot com. This was about 2 years ago. I just went to the website now and see that they offer the same cat (CarSound, referred to as "universal") with a boss/bung already installed for the second O2 sensor. Sweet! I had to have a hole drilled into the long intermediate pipe after the cat, and have a boss/bung welded on to be able to re-install the 2nd O2 sensor. And, the cat is still the same price as what I paid. Since you're in the U.K, I do not think you need a 2nd O2 sensor. I just wanted to remark on it...
Anyway, you are correct about attaching the cat. It just slips into the flex portion of the dp and is then held together with a clamp. My memory slips every now and then (too many dead brain cells from all the college partying...). Best clamps to use are band clamps. They're made of stainless steel so they never rust, and form a seal around the connection, further ensuring no leaks. They cost more (approx. $10 USD per), and you need 7 of them since the tailpipe will use the suppled "C"-clamp style. Definitely worth it. I also used exhaust acoustic sealant around all the connections, and have never had a leak yet.
The orientation of the pipes for the best fit is: dp, cat, bypass pipe, intermediate pipe (cut to fit), curved pipe, primary muffler, curved pipe (goes over rear axle), secondary muffler, tailpipe. Be sure to install the secondary/rear muffler correctly as it is done differently between models (don't even ask how I know about this...headache).
The JT dp does not come with a bracket. Neither does the oem Saab dp. In the stock system, the bracket is attached to the cat via a bolt into a boss, and then attached to the bottom of the engine block. It is a separate item. You will need to have a bracket custom made that can be bolted to the engine block, but welded to the new cat.
Shop around for the best price on the cat. Search the web. Don't purchase from specialty/performance sites. Go to muffler/exhaust sites. I have seen posts by others who paid less than $100 USD. A cat is a cat. The only thing to know is that you want a hi-flow, not a race cat. A race cat is much more expensive and is really only needed in, well, race applications. It uses plates for the catalyst, as opposed to mesh and/or pellets, as is found in normal and hi-flow cats. Be sure it is inlet/outlet 3". I do not know anything about the venting (air) of the cat, but assume you need at least one on it.
Joe
posted by 12.111.48...
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