As shown in this chart, the BearCats product shows overall comparable performance in the NOX and CO efficiencies, and typically higher performance on HC efficiencies.  Because of the nature of OBD-II vehicles, a strong HC conversion combined with a high degree of oxygen storage will result in fewer problems with the check engine light.

     Below we have compiled a chart showing the amount of time in seconds it takes for the converters to light-off, or in other words, to produce a catalytic reaction.  This is a very important characteristic, especially on newer cars, since CARB has cracked down on emissions at engine startup.  In addition, catalysts that light off quickly tend to light off at lower exhaust temperatures.  Since many LEV vehicles operate at lower temperatures, this makes converters that have rapid light off characteristics more suitable for those types of vehicles.   Light-off time also serves as a window to the converters longevity, as catalysts that light-off quickly are also resistant to damage from carbon build up (poisoning) or the subsequent loss of efficiency over time.  Converters that light-off quickly have more readily available surface area and this theoretically and realistically translates to real world durability for ceramic substrates (excluding physically broken catalyst). 

Smaller number indicates better performance.

     As clearly shown in this chart, our product consistently produced a faster light-off time versus competitors units.  These tests were performed concurrently with the above gas conversion tests.  The numbers shown are typical of all test subjects.  The purpose of these charts is not to illustrate extreme values, but rather to show relative performance.  Most units tested met the listed times as shown.

     The rapid light-off of the BearCats converters result from the advanced wash coat application process.  Once these converters have been aged on a vehicle for a period of 500-10,000 miles, the HC efficiency actually increases, in some cases to nearly 100%.  In contrast, competitors products have been observed that function quite well when first installed, but as they age, their efficiency often drops, resulting in CELs several months or several years down the road because of the reduced efficiency.  One of our employees has actually demonstrated this improved HC reaction effect to us.  This individual experienced a failed emissions test, and as a result had some tune-up work performed and had the catalytic converter replaced with a BearCats unit.  The vehicle then passed the emissions test.  One year later, it was time for another test.  No additional work had been performed on the vehicle.  It then passed with a greater margin than when the unit was new, in fact the emissions gases were on the lower end of the typical test range shown for that particular vehicle.

   The next chart illustrates the cost-versus-efficiency ratio, which is basically the amount of catalytic function you get for your money based upon typical prices.  Note that light-off time (action time) heavily influences this chart. Our price for the BearCats product is being used here, and typical Internet vendor pricing is being used for the competitive brands.  Also note that this chart is factoring the ratings of the converters  in terms of the engine displacement and vehicle weight they are designed to handle.  So a converter that is designed to handle a 7.5L/10,000 lbs vehicle will score a much higher value than a converter that is only designed to handle 5.9L/6,000 lbs, even if it costs considerably more, since its efficiency and rating per dollar is still higher.

Larger numbers indicate higher value.


 We have just one more chart, which is a work in progress, and this is an airflow comparison, using a common Flow Bench.  It is important to note that the Flow Bench test is not representative of the most accurate measurements of airflow though an actual exhaust system for several reasons.  But since these products are being tested by the same common criteria, the test is still valid. 

Larger numbers indicate better performance.


     As illustrated in this chart, and, as could be expected, these two test subjects were nearly identical in performance.  While the BearCats unit outperformed the Carsound by a slight margin, for all practical purposes, these units performed identically on the Flow Bench, and this should translate to nearly identical performance on the vehicle.  We have not subjected our full spectrum of products to these tests, but since these units have similar cell densities and similar construction, it stands to reason that each unit will perform comparably to other units in the same size class.

In addition to comparing the efficiencies of our converters versus the Carsound units, we felt we should show you the results of some physical comparisons of the parts. A strong study casing for the converter helps to ensure that the substrate inside remains properly cushioned and packaged to prevent the substrate from fracturing and rattling apart. Carsound has added deep ridges to their casing to make it stronger and prevent flexing. However, this effort is really an attempt to cover an underlying weakness. The material they use is thin and brittle. They have made the materials thinner to save money in manufacturing, and the ridges are just an effort to strengthen the part to compensate. The ridges do have other benefits, and overall are a good idea, but not when they are used to make a weak part stronger. Our converters on the other hand use thicker materials as a starting point. How much thicker? Try 30% thicker, which makes the converter much stronger. In addition, the materials used in our products are much more ductile. While this is not a required feature for the casing, it is helpful for the pipe extensions. This means that the installer can bend or expand the material without breaking it. Below is an image comparing the thickness of the Magnaflow product against ours. The thicker material is also easier to weld to. You can use higher heat settings and work more quickly without burning holes through the material.

And here is an image showing the flexibility comparison of the two products. We took these units and expanded them slowly and carefully to see just how far they would go. We aborted the test on out unit when it had already beaten out competitors unit by a factor of 105%. Our unit at that point still showed no signs of failing, and even though it has stretched considerably, it was still thicker than the baseline Magnaflow. Our units was part# 1005 which is a 2.25" ID (actually 2.30) We expanded it until it achieved an ID of 3.10". The Magnalfow was part# 94004 which was a 2.00" ID (actually it measured precisely 2.05"). We were only able to expand it to 2.44" ID before it catastrophically failed, splitting down the seam and tearing itself loose from the weld at the base of the neck. While you would never expand these materials in this manner under ordinary circumstances, we feel this test shows quite clearly which part can withstand greater stresses. This can mean the difference between having a converter last the rest of the life of your vehicle, be it another 10 - 15 years, or having to be replaced just outside the warranty period of two years. If the converter undergoes minor flexing and uneven expansion due to weaknesses in the materials, the substrate will not be adequately protected and can break more easily.

Another area of weakness is the substrate and packing itself. A converter is surrounded by a heat resistant matting that protects the catalyst and also prevents exhaust gases from bypassing the catalyst by going around it. If the packing is not installed correctly it can allow the converter to shift around inside the can. If it turns even slightly sideways by even a minute angle, it can cause the converter to fail. The shell with cool and contract, putting pressure of the catalyst, either rounding it off, or fracturing it. Our units have stamped indentations that improve the grip of the packing which prevents the catalyst from shifting. Carsound and others often place deep ridges which nest around the substrate. These ridges do prevent exhaust from going around the catalyst, but they also act as contact points where the case can directly touch the converter. If the packing lets the converter slide or twist, these contact points can press against he ceramic and break it.

The difference in the quality of the substrate of our units versus what is used by other companies can actually be demonstrated visually. This is by no means a comparison of the actual efficiency of the converter, but can tell much about how much care and quality goes into the manufacturing to ensure consistency and durability. Below is an image of our converters substrate. Notice the cells all look uniform, the cell walls are evenly formed and appear to be very durable and strong.

Below is an image of a typical Magnaflow. Notice that the cell walls appear to be wavy and uneven. This is not an optical illusion, it is because they are uneven and wavy. Notice how thin the cell walls are. If the converter this substrate is located in where to be hit by say a chunk of blown tire or subjected to excessive vibration it would easily fracture. If the casing were to expand and allow the catalyst to move and bind, it would have little resistance to breaking.

Conclusion

     At the conclusion of this comparison, we at Bear River Converters would like you to know that we feel this is a fair and honest test of some of the most common units.  We will be updating this page with more information as it becomes available.  We would also like to inform our potential customers that metallic converters were excluded from this comparison for several reasons.

1: Many converters with metal substrates are not street legal.

2: Many barely meet Federal requirements for efficiency.

3: Some do light-off quickly, but, contrary to above statements, they do not have good longevity, because they lack surface area and are prone to "poisoning".  Their rapid light-off is related to the fact that relatively small metal substrate tends to heat more quickly than a larger ceramic unit and not because of increased catalytic activity.

4: Actual cell densities may vary by more than 10%, which in turn can result in wildly varying test results in efficiency, light-off time, and airflow.  This is an inherent problem and is related to construction techniques.

5: They tend to be much more expensive and don't have correspondingly good performance to show for it. (On our charts these units would rank very very low)

6: They are best used in off-road or race applications where temperatures may exceed those found in normal street vehicles.  They do have useful applications, such as natural gas, flexible fuel vehicles, or tight applications where other designs may not fit, but these applications tend to inherently run hot and/or produce low emissions anyway.  The converter use in such applications is precautionary or to specifically address NOX and methane emissions.

We may be testing brands from manufacturers such as Catco, Walker, Dynomax, and others, but we expect to see similar test results to the competitive products as shown here, and the only serious variables will likely be durability and price.  We have shown that our product has matched the performance specs of a good benchmark product, while providing a higher overall value, a better warranty and superior construction.

If you feel this information is inaccurate, or have any questions about the procedures and test methods used, please feel free to contact us.