well my 91 1.6 had rusted out down pipe ,broke manifold and lots of holes in exhaust. i installed a hedman header, 2 inch exhaust magna flo muffler, getting tail pipe in the morning. i started it tonite and man its louder then i thought it would be  and it sounds hallow. i might try to put converter back in .  oh well.  still had less in it than if i would have bought just the converter.  plus its my first mod!! matt

I have built a couple of exhausts for 1.6's and my preference is header-cat-resonator-muffler.  The resonator makes a big difference.  It gives it more of a low frequency/power sound.  It also helps keeps it quiet at low/normal rpms but still talks the talk when you romp on it.    

http://cgi.ebay.com/ebaymotors/2-5-Test-Pipe-Resonator-CatLess-Hi-Flow-Straight-CAT_W0QQitemZ380102055340QQihZ025QQcategoryZ133195QQssPageNameZWDVWQQrdZ1QQcmdZViewItem

This is the one I used which fit to my 2.25" pipe.  You can always adapt down to 2" pipe or find a 2.25" one. 

put tailpipe on thie morning and went for a ride . it dont sound bad intill yo uget to 2200 rpms from there to 3200 its really loud. ill put the converter and a res. in next weekend. thanks !! oh the hedman header is real nice pc. i had to bend it a little i mean maybe 1/4 inch it rubbed the auto bellhouseing . but for 155.00 i can live with doing that.