Thanks I talked to the EPA and got a script of what to say. I then called a regional GM department and filed my issue so it would go up the proper chain. I am supposed to get a response tomorrow so I'll keep my fingers crossed. Plan B is likely still cut out the cat, scrap it, and weld up a connecting pipe to fill in where the cat was. I'm not worried about CEL codes as long as the car runs fine. A little dip in MPGs isn't the end of the world, it won't be worse than 1-2 MPG
I have run with nocats on both the stock tune and a Trifecta tune, if u don't mind a random P0XXX code u'll be OK. Our engines can run cleaner catless than all those POS diesel and pre 90 autos so the tree huggers can remain silent.
*** it sure would be nice to see a pic of that magnaflow header***
Cat Clogged? No way. Muffler clogged with a rats nest maybe. I say clean your throttle body out real good with some gumout a rag and even an old toothbrush.
In my car Cel's come and go. Seem's with mine, I drive a little easier for a few days and they go away.
Find Aveo How-to's at my blog. http://aveodiy.blogspot.com/
Timing belt replacement how-to with photos and more....