Did you ever check for O2 sensor 1 working properly? The smell coming from the exhaust is over fueling and its the un-burnt fuel hitting the hot cat when its really bad after a run th fuel burning in the cat can make it glow red hot.
causes of over fueling:
1) Air leak on inlet side - metered air is leaking off but its chucking the correct amount of fuel for the air before it loses some so over fuels.
2) Faulty O2 sensor 1 giving false info to the ECU - Reads the mixture flowing through the exhaust and thinks it running lean so ECU chucks more fuel in to correct it.
3)Faulty air flow meter - if this gives the wrong info to the ECU eg. if it reads lots of air when there's not it will put lots of fuel through for all the air when in actual fact its only getting a small amount of air so over fueling.
4) faulty injector - a sticky injector can get stuck open chucking too much through.
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