Hey Brian,
Went through the ordeal a few years back. On your safety inspection, they are supposed to do a visual to insure all the emissions equip is there.
On the smog test, they only check the emissions...pass or fail. I have heard rumors of the smog guys having mirrors to slide under the vehicle to "have a look".
If you have 2 cats, do you have dual exhaust? True dual was never an option on our trucks and some inspectors will not pass it. Most muffler shops refuse to install dual systems...even WITH dual cats!
Try a new system utilizing 3" single pipe, 3" Flowmaster and 3" cat. You can buy a Catco cat and Flowmaster from Summit and take it to most muffler shops. You will be inpressed with the sound and performance.
You gonna make it to the Midwest K5 Spring Run in Hot Springs, Ark??
todd