Thanks to all who provided suggestions on how to pass the "Dreaded
California Emissions Test"  I was puzzled at how my HC values could be
so high
at idle, and pass at 2500 rpm, and that the Cat could still be the problem.

I dredged up my values from 2 yrs ago, when I also failed on the first
attempt, and passed after putting a new cat on, and I can see that the
numbers
reveal that I was basically in the same situation back then, and that
replacing the cat resolved the problem. At least I have a good idea on
how to pass this time around now.

I guess one question is: "why did the NEW cat fail after 2 yrs" or did I
"kill it" with a poorly tuned engine?
(note i replaced the O2 sensor several months later)

Has anyone else had bad results with the Emico converters?

Does the warranty on these cover failure after 2 yrs? (i guess i should
read the fine print)

Below are the 3 sets of  emission values.

I hope this info, and discussion, might help other Californians, and
those from other strict emission states keep their vanagons on the road!

Values from 2 yrs ago (first attempt failed)
********************************************

rpm    %CO2    %O2    HC(ppm)    CO %    RESULTS
____________________________________________

871    8.4    8.5    637    .93    GROSS POLLUTER

2577    13.0    2.3    70    0.76    PASS

**Replaced Catalytic Converter with EMICO  Model

Values from 2 yrs ago w/ New CAT (second attempt PASSED)
****************************************************

rpm    %CO2    %O2    HC(ppm)    CO %    RESULTS
____________________________________________

861    14.9    .2    63    .01    PASS

2640    14.7    .4    37    .12   PASS

Current Values:
*****************************************************************

rpm    %CO2    %O2    HC(ppm)    CO %    RESULTS
____________________________________________

915    11.9    3.2    424    0.55   GROSS POLLUTER

2571    13.9   .5    66    0.55    PASS