1995 850 NA wagon...I have a hole in the cat, on the top where it really can't be fixed. Two questions:
1. What's the best / most cost efficient way to replace this unit?
2. There's a brace/ plate that is over the cat area...two bolts on the pass side, two on the driver's side. Looks like it either protects the cat or offers structural support. Anywho... tried to unbolt it, the bolts spin out. The nuts are hidden between the floor panel and I can't figure out how to take this plate off...Should I just cut it off, eliminating it? You can't get the cat out without this plate being removed.

 

The cheapest way, with out headaches is to go to a muffler shop and have them cut and weld one in. From what I have heard none of the ones from auto zone, discount, and pep boys dont fit properly. I have even heard of struggles with the ones from fcp.

As far as the cross member, after the 4 bolts are out sometimes you need to just wack it with a mallet. The years of road grime sometimes damn near weld it to the under carriage.
I pulled mine off after installing my exhaust and never put it back. The position of the bolts makes me think its not structural. its just a cross member if your exhaust brackets break off.

 

I pulled mine as well, havent put it back in because of laziness. If you absolutely must take that plate off and the bolts are indeed spinning you will probably have to grind the heads off. I find it odd that they are spinning.

I have a cat if your interested. PM me.

 

I tried three of them from FCP and none worked. I got one from Advance Auto and it didn't work. Finally I went to Monro Muffler and they cut the old on out and welded in a new one. It was also the cheapest option by a good bit too.

 

My wife said if you need at CAT, don't get a DOG.