Yikes... This thread grew very quickly!
Lots of questions to answer...
Roy: I'll be using HKS dumps, HKS front pipes, , APEXi GT-Spec rear.
I don't really fancy chopping up the HKS front pipes to put two 2.5" cats in-line there, but I'll keep it in mind.
AboBob & EvoLee: I shall give CES a call and see what they can tell me. I know that APEXi and Mines publish the flow rates for their cats, and they're excellent flow rates, but for those prices, they'd better be... I'd rather not pay $1500 for a cat if I can help it
cereal: as far as I know, in relation to cats, the measurement is across the actual honeycomb material, so with a 4" cat, you can weld 3" flanges to it and bolt it onto your 3" system, but since the honeycomb structure is restrictive, flaring out to a 4" cross section honeycomb will still be less of a restriction than a 3" honeycomb section, even though your flanges are 3"
I have no idea whether a 4" cat will fit under the car...
I think the main point of contention was that the honeycomb material used in most of these aftermarket cats were inferior, and so even though they were larger (cross section) than stock cats, they didn't actually lessen the restriction, so they were useless.