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wth, it cracked the valve cover? That's rather extreme... I don't know that the cats are the things to blame on this one.. I know you said it happened right after the install but I've had enough secondary things pop up after I do an unrelated job on my car that I believe in coincidences now.
Also, doesn't that material look more like paper on the piston? Do you have a paper air filter?
I suppose it's possible that with a sufficient blockage; when the intake valve opens at the top, just before the exhaust closes (so during scavenging) that you could actually get back flow. It just seems so unlikely. My dad's truck years ago had the cat melt into a near solid blockage and it just had no power; no other damage (granted it's a truck engine).
*Also not a professional mechanic; just some guy on the internet.
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