Abstract: A catalytic converter subassembly having at least one component inserted during the manufacture of a cast exhaust manifold, thereby eliminating a costly and undesirable manifold to converter weld. The method and converter subassembly comprise a converter shell for housing a catalyst substrate adapted to be securely attached to an exhaust manifold during manufacture of the manifold to eliminate an undesirable weld between the manifold and converter.

Abstract: A catalytic converter comprises an exhaust manifold comprising a manifold wall; a catalytic converter shell, wherein a portion of the catalytic converter shell is disposed within the manifold wall; and a catalyst substrate disposed in the catalytic converter shell.

Abstract: A method of making a gas treatment device, the method includes projecting a laser line onto a side of substrate from a laser line generator angled away from a viewing source; projecting a laser dot onto the substrate from a laser dot generator located above the viewing source; verifying an alignment of the substrate with at least one of: another substrate and a housing by comparing the laser line projection on the substrate to the laser dot projection on the substrate, wherein the alignment is verified when the laser line projection and the laser dot projection are co-linear; and stuffing the substrate into the housing.

Abstract: A catalytic converter subassembly having at least one component inserted during the manufacture of a cast exhaust manifold, thereby eliminating a costly and undesirable manifold to converter weld.