This is a bit of a long story, but any insight would be appreciated.
I have an EJ251 (Non-CARB) engine mated to the 4EAT that will not stop throwing P0420 despite having a new exhaust, two new cats, two new oxygen sensors, and an exhaust O2 sensor spacer.
In the summer of 2018, an exhaust shop in VA scrapped the whole exhaust (was rusted beyond use) and used an aftermarket UEL header (similar configuration to this https://i.ytimg.com/vi/QxCr6KroLU4/hqdefault.jpg) with two new catalytic converters, two new oxygen sensors, and a 2.5" stainless catback. I then moved to NC. This exhaust worked for 1,000 miles before it threw P0420. I leak checked it and found it leaked at the header flange to the cat. Needed head gaskets done at the time, so I ignored it and the car went down for 6 months while I performed various engine rebuild things.
In summer 2019, the car was running and I took it to a shop for A/C and exhaust fixing. In "fixing" it, they also put in 1 new O2 sensor and I don't know why. When they gave it back to me, they said it had rod knock and that the exhaust still leaked. It sounded a lot like rod knock (which it didn't have before I dropped it off), but ended up not being it. The car sat until January 2020 before I felt like dealing with it again and it turned out that the second catalytic converter (which had roughly 1,500 miles on it) had failed (matrix was sideways in the housing). Had a shop fix it and leak check it, still threw P0420. Took it back to them and they found that the FIRST CAT was completely missing (also had 1,500 miles on it: no clue where or when it went, but it probably is what destroyed the second cat). The shop put a LEV certified cat in as the new first cat, said it didn't leak and it STILL threw P0420.
They troubleshot the voltages at idle and it was reading happy. Cleared the code and drove it 50 miles (at 50 MPH) and no codes. Threw a check engine light the next day almost immediately after accelerating to 60 MPH on the highway. Took it back and they put an O2 spacer in. I then drove it 50 miles (at 60 MPH) with no check engine lights. It then threw P0420 on the drive to work the next morning.
My next thought was maybe the aftermarket UEL header was getting too cold at highway speed, so I put the stock skid plate back on the car to help hold the heat in. The car STILL throws P0420 on the highway.
I did perform my own leak check and there is a small leak in the header on a weld the shop in VA performed. I do not believe it is big enough to cause P0420 on a brand new cat. My IAC valve was cleaned 1,500 miles ago and the code does not show up at idle. I am not throwing ANY other codes. I stethoscoped my injectors and they are all ticking over correctly.
The shop recommends replacing the O2 sensors with Denso sensors (I have no clue what is in there now), but before I spend another cent on this thing, I want some outside advice. Thank you for taking the time to read this, feel free to ask any other questions I may have overlooked.