2002 Prius with exhaust holes in the two piece catalytic converter!!

Find an independent muffler shop in your area.
They can answer both questions........probably better than a dealer can.

My guesses:
They can get you a replacement a LOT cheaper than OEM.
Trying to weld a hole in an exhaust pipe or muffler is like pounding sand down a rat hole.

 

Roy from canada trying to help --- I wrapped a stainless steel sheet of metal I got from a metal scrap yard ( stainless steel sink) around the body of the area with holes and held it there temporarily with a nut bolts and hole strap, before that I coated the metal sheet with a material that would allow the silver solder to melt and run between the converter steel and the patch when I heated the pipe patch. You will need an oxy act welder to heat up the patch and weld it to the exhaust.

or you can buy a new converter that welds on but any missallignment will cause the pipe to not fit to the manifold properly

cheap quick fix is to buy a product called inferno repair that requires high heat to cure it ( the converter gets very hot and will make a good cure) use a small stainless steel patch over the hole (under the patch put the inferno product against the hole) and the apply another coat over the top of the patch - the product cured like iron and is still working an my manifold repair after 6 months. Be sure it is the high temperature (2200 deg) material that gets harder and harder with heat. Cost about $10 per small bottle. Follow directions to allow air cure for 4 hours before starting the car for the converter to heat up and do a full cure. The inferno repair material starts off as a soft putty like material in a small bottle just mix it well and apply.

 

Hi Roy here from canada. Let us know how you did the repair and how long it lasts-- may help others in the future.

Roy