First off, my stock exhaust is like this: 2" downpipe until just before the cat where it goes to 2.5" and after the cat it stays at 2.5". Now here is my dilemma, i have a header and the collector is 2.5" and my flange barely bolts up correctly due to the size difference. I was wondering if i could just make a custom 2.5" downpipe? So, my exhaust pipe will stay consistent all the way through. What would the pros and cons be to doing this?


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A custom exhaust shop should be able to do anything you want for a price.

But I forget many of you don’t have access to shops like this it depends on where you live small town USA has few choices to offer.

I miss southern California there is a specialist for just about everything within a 15 minutes’ drive.

 

I'm not concerned about the task of making the pipe. I have a welder and exhaust pipe is cheap. I'm more concerned about the pros and cons of doing this. Will I loose exhaust velocity? Power gains or losses?


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If you have all the tools and skill set to do this the only way to know what will happen is to just make one and see what happens.

If you can DIY the piping and you say you can do it what’s stopping you? Make two or three different size exhausts drive the thing and find out

 

Well, I did it. I went with 2.5". I also routed the pipe differently so it is straighter. This is just a prototype. I plan on getting one mandrel bent like this. Gain wise, it is much smoother and responsive, and pulls harder on the top end. Surprisingly hardly lost any bottom end.

http://s1274.photobucket.com/albums/y421/00daksport25/


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That’s awesome man only thing that sucks is the large bend constricts the flow some especially with it accordioned like it is the ripples will cause some air turbulence. Those are very hard to do without causing the ripples but it can be done.

1021121508_zps7dd539d4.jpg

 

Yea, I hate that bend. I'm just going to buy a mandrel bent 90 or 100 degree bend and weld it in place. That alone should open it up a lot more.


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longer radius or multiple pieces I have a formula from sheet metal school to tell you the degree you have to cut for a longer radius and the best thing is you don't have to bend the pipe

 

WOW

I just realized something on my 98 the cat is way in the back of the truck under the bed not like your cat that is just after the exhaust manifold.

Now it could be the shop that replaced all my exhaust system moved the cat back there they did a great job for me larger tubing and great bends very smooth they installed a Magnaflow cat and high end muff that I think is a magnaflow 40 all stainless steel sounds great a low throbbing but quiet still almost like stock.



Kind of weird and probably help my 2.5 breath better I bet

 

What you saw me take off was my precat. I have a full size cat right after the crossmember.


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