How about an exhaust leak before the 1st cat? could that have been responsible?
I would say yes, perhaps. Exhaust leak in front of the first O2 sensor could draw oxygen into the exhaust. The sensor would see this additional oxygen as indicating not enough fuel present to burn all the oxygen so the ECM would add more. The exhaust then would be rich in fuel entering the cat which could damage it. I think, however, that you would have very positive fuel trim which would set a code.
Up to this point, we have been assuming that the P0420 is being caused by a bad cat. The FSM identifies other reasons which should be excluded before indicting the cat as follows:
1. Gas leakage on exhaust system
2. A/F sensor (bank 1 sensor 1)
3. Heated oxygen sensor (bank 1 sensor 2)
And Finally....4. Three-way catalytic converter
One thing you can do to check cat efficiency is check it's temperature using a non-contact infrared thermometer. It should be a lot hotter than the exhaust gasses entering it if it is working properly - operating cat temp is in the +1200F range. It can get way hotter if there is lots of unburned fuel getting to it and eventually the honeycomb melts (=dead cat...can sometimes plug). If it is dead, it is no hotter than exhaust gas. So, using the non-contact thermometer, the temp of the exhaust pipe right at the discharge end of the cat should be higher than the pipe entering the cat after the engine has been running a while.
In case you are curious (like me), short video on how cats work....
https://www.youtube.com/watch?v=rmtFp-SV0tY
Forgive me if I rambled on.....
Buckaroo