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I don't mind the loudness, drone, of turbo hiss (not to mention normal clatter) of an upgraded exhaust in my Excursion but it makes for a louder trip for the family and wakes the neighbors.
Frankly I dont really care about the loudness or "Note" of the exhaust - I am interested in making the 6.0 as quiet as possible. Currently I have researched found that there is very little that I can do to improve performance and make it quieter. I have 50k on the Ex and plan to keep it for a long time. Here are some initial thoughts.
4 Inch Cat Back Exhaust
Upgraded Cat
Better Muffler - some suggest 2 in sequence to reduce sound
Heat Tape over the entire length of the exhaust system end to end. Multiple layers if room.
Road BlockR Sound Deadener over all of the floor area but especially in the Firewall area with multiple layers. Spray for the tight areas and doors.
There are aftermarket mufflers that are free flowing/no restriction that make a big impact on sound. Most of that sound has to do with it being 4". I have delete pipes and with those there is no drone.
You can also cut the exhaust ext to face more to the back. I have my exit at a 45* angle. Stock exhaust exit is directly to the side.
During the colder engine temps, when 5w-40 engine oil is used, the injection noise is not as much as 15w-40 engine oil.
Some have reported that after they use rev-x, the injection noise has decreased.
I don't think you would need two mufflers. Most of the noise you are hearing inside the cab is engine noise I doubt you can really even hear the exhaust.
second question: Kill noise with windows up or down?
Right now, I can't hear my motor when the windows are up and A/C is on. Radio is very low...typically 1.5 to 2 bars. I've never heard my exhaust, but it's bone stock at moment. I do occasionally hear some turbo whistle.
Windows down...it's a cacaphony of sound. Tons of turbo whistle and clattering. I've thought about putting a hood liner on and lining the inside of the fenders. Also perhaps a custom skirt around the motor to seal the wheel wells for noise.
Problem with that stuff is trapping moisture against body panels. Never a good idea. Especially where I live with all the salt spray
second question: Kill noise with windows up or down?
Right now, I can't hear my motor when the windows are up and A/C is on. Radio is very low...typically 1.5 to 2 bars. I've never heard my exhaust, but it's bone stock at moment. I do occasionally hear some turbo whistle.
Windows down...it's a cacaphony of sound. Tons of turbo whistle and clattering. I've thought about putting a hood liner on and lining the inside of the fenders. Also perhaps a custom skirt around the motor to seal the wheel wells for noise.
Problem with that stuff is trapping moisture against body panels. Never a good idea. Especially where I live with all the salt spray
Salt spray here too - only here it is to knock down the ice on the roads...
I am more interested in windows up quietness but I assume that reducing external noise will also help internally.