Abstract: The present invention involves reduction of exhaust emissions through the use of a catalytic converter which has at least one sensor disposed between two or more beds of solid catalysts, or mid-bed, and which does not include an external heat shield.

Abstract: A method of assembling exhaust components comprising the steps of: (a) providing an exhaust plate or other exhaust component having a first side, a second side, and an embossment, the embossment defining an aperture and a void contiguous with the aperture; (b) providing an exhaust pipe or other mating exhaust component having an end portion having a leading end, the end portion sized to be received by the void; (c) inserting the end portion of the exhaust pipe into the void; and (d) bending a portion of the embossment over the leading end of the end portion to lock the exhaust plate to the exhaust pipe. Step (d) may include flaring the embossment and a leading portion of the end portion of the exhaust pipe. Step (d) may be performed by punching the embossment to deform the embossment and the leading portion of the end portion of the exhaust pipe.

Abstract: A method of assembling exhaust components comprising the steps of: (a) providing an exhaust plate or other exhaust component having a first side, a second side, and an embossment, the embossment defining an aperture and a void contiguous with the aperture; (b) providing an exhaust pipe or other mating exhaust component having an end portion having a leading end, the end portion sized to be received by the void; (c) inserting the end portion of the exhaust pipe into the void; and (d) bending a portion of the embossment over the leading end of the end portion to lock the exhaust plate to the exhaust pipe. Step (d) may include flaring the embossment and a leading portion of the end portion of the exhaust pipe. Step (d) may be performed by punching the embossment to deform the embossment and the leading portion of the end portion of the exhaust pipe.

Abstract: A system is provided for orienting two engaged exhaust pipes or conduits and maintaining a proper orientation between those pipes after engagement to provide a proper alignment between the pipes. The system includes a tab formed on one of the pipes and a tab-receiving notch formed on the other of the pipes.

Abstract: An exhaust manifold includes an inner shell providing a first flange having an interior and exterior surface and an outer shell cooperating with the inner shell to define an interior region therebetween. The outer shell provides a second flange having an exterior surface which is situated in spaced-apart relation to the interior surface of the first flange to form a flange-receiving space therebetween. The flange-receiving space provides an access opening into the interior region intermediate the inner and outer shells. At least one baffle is situated in the interior region. The at least one baffle includes a mounting flange nested between the first and second flanges and positioned in the flange-receiving space to extend through the access opening so that a distal portion of the mounting flange is exposed to exterior surroundings outside of the interior region defined by the inner and outer shells. Configuration of the at least one baffle is disclosed for use in single and dual exhaust manifolds.

Abstract: A tuned exhaust manifold is provided for attachment to an engine having a plurality of exhaust ports. The manifold includes an inner and outer shell joined together to form an exhaust chamber and an inwardly-opening flange-receiving space at a split line defined by the union of the inner and outer shells. Captive tuning baffles are dropped in place and positioned in the exhaust chamber to isolate individual engine exhaust ports for engine performance tuning. Each baffle includes a flange trapped in the space between the inner and outer shells to retain the baffle in a predetermined position within the exhaust chamber. The baffles are arranged in a predetermined pattern within the exhaust manifold to define separate passgeways extending from exhaust inlet openings formed in the inner shell toward one or more exhaust openings of the manifold. Tuning is accomplished by configuring and placing the baffles to control the flow of exhaust from each engine exhaust port through the exhaust manifold.