Catalytic convertor rattle !!!

[Maestrochris]

I have a 1.3 clubman, 1994 which last week started to produce a rattle when the engine was on load. It it now getting worse. Have traced it to the catalytic convertor which when tapped makes the same noise so something inside has broken. ( The exhaust/mountings are in good order) Does anyone know if this is a problem that will go away, or get worse and is the only solution a new cat and how much will that cost ??

Thanks Chris

[E_T_V]

Do you know what emissions test the car has to pass? If it is just the standard 1200ppm HC's and 3.5%CO MAX then I know you shouldn't but you could just remove the guts from your existing cat so that it is just an empty box. This would remove the rattle and restriction, and would essentially be free if you DIY'd it.

[BenGMain]

Sneaky, I like it!

[Maestrochris]

Thanks for this, thats my type of solution. The whole point of a maestro is that it is simple with few gadgets to go wrong and if I can bin the cat thats even better. By the way, over the last day or so the noise is reducing as I guess I force the broken bits out the exhaust.

Cheers Chris

[E_T_V]

Quite often you'll find it is the heat shield on the cat that is what is rattling. Either fix it, wrap some wire around it or rip it off. Lindz's cat rattles in the same way. However if the cat has broken up internally then get a long chisel out and simply smash out the remains (don't breathe the dust). That is assuming it only has to meet the 1200ppm HC's and 3.5%CO rules (as non cat maestros will easily pass that one).