Similar problem here Tony but I have yet to isolate it. I will replace the header/cat unit if that is where the problem is. Friend had similar noise and it was the INTERIOR of the cat that was crumbled and rattling around. Now that my part of the globe is beginning to warm up a bit, I hope to be able to get under the car and start tapping around with a rubber hammer and see if I can get the thing to make the noise. If it is just the shields, I think you can tighten them down and stop the noise. Keep me posted on your findings.
AkL 
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'02, Arctic Silver/Graphite Gray, 2.7, TIP, 2nd cat delete, Charlie Chan muffler,de-ambered, Braille Battery, clear tailights, painted bumperettes, clear third brake light, M030 sway bars, F shock tower braces, clear rear deck, '03 side vents.  15mm spacers fore & aft.
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Mean Motor Scooter
Hybrid Mode
