hey everyone i'm new to this forum and i just wanted some feedback and opinions for my exhaust setup. i have an 04 f150 (new body style) 4x4 with 4.6. currently i cut off 2 of the 4 catalytic converters (the 2 behind the o2 sensors) and have turn downs just below the cab, giving me true duals. i have enjoyed the sound and rumble but wanted a little more performance instead of just sound, so i purchased pacesetter long tube headers for my truck
Amazon.com: PaceSetter 70-2328 Long Tube Header for 4WD 4.6L Ford F150 2004-08: Automotive
now as i'm sure u know if ur going to give advice, the remaining 2 cats are at the bend of the exhaust so i'm going to have to remove them (darn ). anyways getting to my question, i really don't want to run open headers, so what kind of exhaust setup can i run off the back of the headers? remember i have limited space to fit between the frame and t-case and it has to stop before my gas tank on the driver's side. here's some pics please give me some feedback.
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note the distance to the gas tank. can't get too much closer

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sorry the pics are so big. not all that computer savvy so if someone wants to resize them that would be great.

 

this would be super short, IMO, i would have an exhaust shop make one that exits out from the side or back but this should work
Flowtech 50231FLT - FlowTech Purple Hornie Mufflers - Overview - SummitRacing.com

 

i thought about glasspacks but from an open header to just a glasspack i think will still be really loud. i don't care how short it is, really it has to be pretty short to stay equal length true duals and not burn up my gas tank. i'm thinking a chambered muffler of some type like a flowmaster 40 or 50 series turned sideways but i don't think it'll fit tucked up and under my frame

 

i had the header mufflers i posted above on my 67 and they are not loud, i sold them because they were to damn big for under my car and they were too quiet but that would change when the packing burns out

 

they weren't loud? to ur standards? i need daily drivable. i don't care about roaring during acceleration but i can't have it waking up the entire neighborhood when i leave my house at 5 every morning

 

my open flowmaster 40's were louder, dont get me wrong i only ran them for 15min or so and when the packing is gone i bet the get louder but they were not as loud as i thought they would be by far.

 

That works for me. I've got a buddy that owns a muffler shop so I'll try them both out (I'm sure he's got a glasspack and flowmaster laying around at the shop) and I'll go with what sounds the best. I do like the purple pipes, so if I go with a glasspack it'll probably be those. Thanks for the find and input

 

let me know how it works out, i think im going to put an exhaust cutout in my truck so i can have the best of both. quiet when i need to be and open straight pipe when i want to be loud at the flip of a switch
2.5" Electric Exhaust DUMPS Cut out STAINLESS Cutouts - eBay (item 250773918079 end time Mar-16-11 15:21:01 PDT)

 

I had those on my K5, yeah I know it's a chevy but it was my first truck, and they leaked. It never made a good seal so I was always running slightly open header. Personally I didn't really have a prob with it, but I'm just letting u know for legality reasons (not street legal).

I should have everything here and setup by this weekend so I'll definitely let u know how it goes

 

if it leaks i will put a block off plate with gasket when getting inspected. was yours the same brand? i will only be using one and it will be where my catback starts but if it leaks it will make me crazy and i will have to remove it.

 

they look similar but not the same and i don't remember the brand i had. i got mine from JCWhitney way back in the day and maybe they've improved them since then, but if it will bother u, i'd highly recommend against it

 

not exactly what i had but similar
Pypes Performance Exhaust HVE10K - Pypes Electric Cutouts - Overview - SummitRacing.com

what my mechanic at the time told me to get if really had to have dumps and at the same time be able to change to street legal
Pypes Performance Exhaust XVX10F - Pypes X-Pipe Dumps - Overview - SummitRacing.com
and add end caps

i remember everything being a lot cheaper back then

 

my headers arrived today..... they're a lot longer than i thought they would be. yes i know, they're "long-tube" headers, but i expected them to come to about where the cat ends. they went about 5" past that. now i have roughly 18" between the end of the header and the front of my gas tank on the driver's side. i can't run open header (as much as i'd love to), so what can i fit in less than 15" with a 6" width and 8" height?

i won't be able to stop by my buddy's muffler shop until saturday so it gives me alittle bit of time to come up with a solution other than what i know he will suggest (running piping from the driver's side to the passenger side and installing regular mufflers). i don't want to do this bc then it won't be equal length.

 

what pipe size?

 

outlet on the headers are 3"