My friend Josh, Army19ksvt on here, had the same thing happen with his Jay Racing HFC. He noticed his car got a lil louder over time. So when we took off his manifold, we checked the HFC and noticed there was not catalyst left. But he was gonna hollow it out anyway with the turbo build and wasn't worried about a refund or anything. But just wanted to share that i've seen the same thing your talking about happen before.
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August 2009 ROTM
FF09 best of show - 3rd place
FF09 bracket racing - 1st place