Clogged Catalytic Converter Options

[barterj]

Last summer the first catalytic converter melted and clogged the second one. I punched out the second and replaced the first one since that is the one with 2 oxygen sensors connected to it. Since I replaced the cat I've put about 20K miles on my car. The cat. melted and got clogged again.

Does anyone know any reason(s) why this is happening?
-220K miles (2.2L)
-Engine is running at normal temp, never over heats
-Doesn't burn hardly any oil, maybe half a quart every 3,000 miles.
-It is eating gas, though i think that was from the cat being clogged and it needing extra to keep the engine running under the increased back pressure from the clogged converter.

Here is a pic of what it looked like before I punched it out today

[Special_Edy]

The extra fuel is not being burnt, it is going into the exhaust and burning when it hits the superheated surface of the catalytic converter. This causes the catalytic converter to melt. Replacing the catalytic converter will result in the destruction of the new catalytic converter. Fix the excess fuel problem before you worry about anything else.

Lol you could always buy an oxygen sensor simulator("off road use only" of course) so that you can delete the cat and second O2 sensor. Maybe $60-$150.

[Bitter]

The extra fuel is not being burnt, it is going into the exhaust and burning when it hits the superheated surface of the catalytic converter. This causes the catalytic converter to melt. Replacing the catalytic converter will result in the destruction of the new catalytic converter. Fix the excess fuel problem before you worry about anything else.

PRECISELY. You need to know why you're running so rich. Bad sensor, bad plug wires, plugs, cap, rotor, weak coil, low compression, leaky injector, etc etc. That is 100% fuel damaged catalyst there. Classic melted.