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My car went to my favorite custom exhaust shop this morning for a thorough inspection. It seems that the flange on the front of the secondary cat had eroded and the gasket that connects the front and rear cats could no longer seal the system.
They cut just behind and in front of the flange and welded in a 5" piece of stainless tubing on each side, connecting the pipes from the front cats directly to the secondary cat.
They also only cut away enough of the heat shields to permit the sawing and rewelding. Any loose play was eliminated by spot welding them directly to the pipes.
Total cost: $100
I have the part he cut off and will take close up photos of the hole in the flange. Just made of plain steel and not stainless
There is an federal EPA law covering such emission parts like these, starting in 1996. They are covered under warranty for 8 years/80,000 miles. But the fine print only covers defects in workmanship and loss of efficiency of the cat itself, not deterioration of the attaching points. My car was within 200 miles of the 80K cutoff.
This seems to be a much better solution for the moment. I have access to primary and secondary cats if I should need to use them in the future. My sincere thanks for all here who took the time to respond to this post. You are all the greatest!!
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Subaru Ambassador
1996 Polo Green LSi #216 ..138,100 miles. ..SOLD
JFICX8659TH100216.....Date of Manufacture: November 16, 1995.....
Fuji Heavy Industries..Ōta North Plant....Ōta City,. Gunma Prefecture, Japan
In-Service Date: January 2, 1997
"The Pristine Green Polo Machine”
First Polo Green on the Network
First Clear front turn signals, JDM Alcyone hood emblem, rear panel, and BOXER engine cover on the Network (US) (2000)
First 5000K HID factory fog lights (2007)
First SVX JDM BBS wheels on a USDM SVX (2013)
HID lighting (5000K) for headlight and H3 fog lights, PIAA SuperExtreme 120W high beams, rebuilt EG33 longblock, Cometic head gaskets, Phase II flexplate, AMR aluminum radiator with custom silicone hoses, 160A high-output alternator in aluminum-ceramic coated case, new design alternator wiring upgrade v.4, rare factory headlight protectors, refinished JDM BBS mesh aluminum wheels and custom, polished billet aluminum new hex center caps, LED grille mod, R1 Concepts high-carbon cryo slotted rotors, Akebono ceramic pads, Goodridge S/S braided brake lines, Smallcar Stage 1 shift kit, ThermalTech aluminum/ceramic-coated valve covers, Energy Suspension urethane front & rear swaybar bushings, Bontrager22 rear swaybar with QS Components Chromoly Teflon/Kevlar endlinks, "$15.00/5 minute" suspension mod. Hella Supertone horns, Custom stainless steel exhaust system with 2" headpipes, Magnaflow cats, AeroTurbine AR25 resonator /AWD "Bullet" muffler.
R.I.P. 2010 Subaru Outback Limited 2.5 CVT...338,000 miles. Totaled by a 1,300 lb. COW March 4, 2016 
2014 Hyundai Avante Limited ...178,000 miles. Actually quieter and smoother than the Outback 
2007 Mazda Miata MX-5 PRHT...102,000 miles.
Plenty of parts, service and windshields. 
4th Registered Network member —2/21/2001
My NEW locker..I...My Email..I..Wikipedia/SVX .
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