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We just started a series of technical articles that explain how catalytic converters are made, how they work, why people steal them, and why you should probably be running one on your Corvette. This is just part one, we'll have part two up in a few weeks. Check it out and let us know what you think or if you have any questions.
What is the CPI on your cats? I did a ton of R&D years ago on cats and we experimented with anything from 100cpi to 1200cpi. The 1200's were a PITA to coat, so many plugged channels in them, tremendous backpressure, but boy did they work at converting the incoming gases! We found 300 to 600 cpi was the sweetspot.