I had the same problem with my Bassani o/r X pipe. I had to cut the pipe, on the side that had the leak, bolt the piece to the header, and then weld a sleeve to cover the gap. Looks bad but works. I don't know if you will have room to do so with the cats, but It's worth a look.
Caymon
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'90 GT Under construction
Best E.T. = Fast @ High Speeds - OK So I Lie. So What!!!  
04 F-150 STX 4.2L 5 spd
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