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An experiment was performed with a 1.3L catalytic converter design containing a front and rear catalyst each having a volume of 0.65 liters. This investigation varied the front catalyst parameters to study the effects of 1) substrate diameter, 2) substrate cell density, 3) Pd loading and 4) Rh loading on the FTP emissions on three different vehicles. Engine displacement varied from 2.4L to 4.7L. Eight different converters were built defined by a Taguchi L-8 array. Cold flow converter restriction results show the tradeoff in converter restriction between substrate cell density and substrate diameter. Vehicle FTP emissions show how the three vehicles are sensitive to the four parameters investigated. Platinum Group Metals (PGM) prices and Federal Test Procedure (FTP) emissions were used to define the emission value between the substrate properties of diameter and cell density to palladium (Pd) and rhodium (Rh) concentrations.