i just got my aero4040xl in the mail today and my aero 4-5 inch tip(DT4050C). I am putting the aero4040xl where the cat is. Will it fit over the existing 4 " exhaust or will it need to be welded on? I was wanting to slide it over existing exhaust and use 2 pop rivets to hold it together and then slide a 4" step/bandclamp overtop and impact the clamp tight. can i do this or not? seems like the aero is same size as exhaust?

 

your best bet is going to be welded. . .however some clamps will work, no need to rivet.

 

the rivet might not be such a bad idea if you are going the clamp route! i had my exhaust clamped for a while and one day it just came un-done, then i clamped it again and about a month later it came un-done again and i almost lost my aero to the dude driving behind me. i decided to have mine welded after the close call of losing a 200$ muffler, but rivets would be good to!

 

okay. but what i mean is will it slide over stock 4 inch exhaust? or is it the same diameter of the 4 inch exhaust?

 

It will slide right over the 4" pipe and will slide in 3" from each end. I don't know how loose or tight it is as I didn't install it my slf. But when I watched him slide it on, it looked as if it went right on pretty easy.

 

However you install it, if I were you I'd mount it where the stock muffler was, not the cat.

 

Mayfair....what are the advantages/disadvantages to installing it where the stock muffler was?

 

Just my 2 cents but I would mount it as far back as you can. Not for sound reasons but just to be close to the hangers. I couple of things I noticed after installing mine is that the long section of pipe comeing from the turbo downpipe back to the Aero that is in the stock muffler location, now vibrates Heavily at idle. It doesn't rattle or anything but you'll be shocked when you crawl under there and see it shaking.
That tells me that all the wieght from the cat and the stock muffler must have prevented the exhaust from vibrating. But now with all that wieght gone, it wants to vibrate it's *** off.
Since the Aero 4040 is so light wieght, I would guess that it will still vibrate like this if installed where the cat is. There are no hangers till you get to the muffler. Maybe it doesn't vibrate like this on all trucks but if the Aero were where my cat was and it vibrated like this, I would definatly feel it inside the cab at idle. And would probably get very annoying after a while.
Hold off on installing it and I will get a video of mine idleing and you'll see what I mean.

 

I have mine all band clamp. any other type of clamp is worthless. 2 years on my clamps and no issues at all.

 

Well, beased on what I've been hearing from different folks that have mounted it both ways, it seems to me the people who mount the Aero where the cat was seem to be the ones who complain of a drone noise, whereas everyone that has mounted it where the stock muffler was hasn't had the drone sound at all. Aero also reccomends that it be mounted where the sock muffler was.

Not everyone complains of a drone sound, but those who do seem to be the ones who have mounted it where the cat was.