Highlights• Development of highly stable and active cathode catalyst supports is reported.• Pt nanoparticles deposited on the stable supports show enhanced catalytic activity.• Potential holding at 1.2V showed enhanced support stability in H 2 -air polarization.• Rated power densities of 0.18-0.23 g Pt kW −1 are achieved with the novel catalysts. Abstract Novel procedures are developed for the synthesis of highly stable carbon composite catalyst supports (CCCS-800 °C and CCCS-1100 °C) and an activated carbon composite catalyst support (A-CCCS). These supports are synthesized through: (i) surface modification with acids and inclusion of oxygen groups, (ii) metal-catalyzed pyrolysis, and (iii) chemical leaching to remove excess metal used to dope the support. The procedure results in increasing carbon graphitization and inclusion of non-metallic active sites on the support surface. Catalytic activity of CCCS indicates an onset potential of 0.86 V for the oxygen reduction reaction (ORR) with well-defined kinetic and mass-transfer regions and ~2.5% H 2 O 2 production in rotating ring disk electrode (RRDE) studies. Support stability studies at 1.2 V constant potential holding for 400 h indicate high stability for the 30% Pt/A-CCCS catalyst with a cell potential loss of 27 mV at 800 mA cm −2 under H 2 -air, 32% mass activity loss, and 30% ECSA loss. Performance evaluation in polymer electrolyte membrane (PEM) fuel cell shows power densities (rated) of 0.18 and 0.23 g Pt kW −1 for the 30% Pt/A-CCCS and 30% Pt/CCCS-800 °C catalysts, respectively. The stabilities of various supports developed in this study are compared with those of a commercial Pt/C catalyst.