Anyone run without a cat?

One last thing. Stewart, Ford did have cats in all the trucks coming off of the assembly line. There was an old man named "Lieutenant Stenches Lee McPhaterson M.D." that drove the trucks from the end of the line to the parking lot where they waited to be loaded on trucks. He always carried a small tin with him and no one ever understood why until he dropped it one day. As he got out of the very last EX to be parked from the line it slipped out of his pocket and when it hit the ground ashes went everywhere! It was his deceased cat that he had cremated and put in the tin. So every EX actually had one in it when it was built. Little known fact, kind of disappointed you didn't know that... Should you resign from being a mod now? I think it's only right in light of this recent development.

That got you another greenie!
As for mod duties, thankfully one of the requirements for being a mod isn't knowing the vehicle the forum covers. It helps, but it isn't a "must" since mods do more than facilitate conversation and help with tech.

Stewart
I now have a completely custom dual exhaust, which I designed.
2.5" pipe from each down pipe all the way back, totally separate with some small mufflers on the very end.
I noticed a mileage improvement after removing the CAT on the stock setup, and another slight mileage improvement with the true dual setup.
Currently I get 11.4MPG mixed, pretty much about 50/50, I spend a lot of time putting around town doing errands, but I also do a lot of long trips and 30 miles of highway commute every day.
The dual exhaust setup makes a noticeable difference as the engine winds up to higher RPMs, but may have robbed me a little bit on the bottom end.
I don't care if you are skeptical, I know it makes a difference, not necessarily in power but in mileage. When I bought the truck bone stock the lie-o-meter said 11.2 MPG. I am now getting slightly better than that with an 8" lift and 35" tires and the stock 3.73 gears. I drive it like I stole it on the open road and creep real slow in town.
The things you will notice most about removing the CAT are, it stinks, a lot, it could choke a rhino. Also the CAT muffles the exhaust sound more than the muffler. No CAT is real real loud. That is most of the reason that I creep real slow around town. If I punch it it will set of car alarms, I am not kidding or exaggerating at all. The bark this thing has being basically straight piped is deafening.
I am thinking of getting some larger mufflers and putting them in the middle with an X-pipe towards the front and putting some big six inch tips on the end. That should reduce the bark a lot and lower the tone, right now it is raspy and crackles.
What I also find interesting is that the flutter is still present at about 2100 RPMs. The reason I didn't put an X-Pipe on is because I thought the true dual separate pipes design would eliminate the flutter sound. The flutter is considerably reduced because of the amount of flow I have. I used to have the stock y-pipe no cat and a Flowmaster Super44. The sound at 2K - 2.4K RPMs was awful. It was way louder than my current dual setup. The combination of the exhaust fighting its way through that terrible y-pipe and then bouncing around in the baffled muffler was horrible. The dual exhaust setup that I have now is way quieter. I think with a couple more tweaks I could get it to the point where it isn't stupid loud and doesn't crackle.
The next mod I have in mind is 5.38 gears, I am going to do that in the next couple weeks or so. That will change the sound a lot, because all the shift points will change (particularly the one at about 2100RPM) Also with the V10 being able to wind up it won't be bogged down like it is now. For example if I sit in park and wind up the engine it is pretty quiet, but if I go WOT from a dead stop it makes a ton of noise because the engine is loaded and geared all wrong.
I am pretty psyched to get those gears, this big old pig should be much more motivated.
Im thinking of going with a super10 muffler. I don't like the high pitch at certain rpms and the crackle like you mentioned.
I'm still stock in front of from where the cat originally was. From there its 3 in to dual 2.5 pipes.
Get some Dynomax Race Bullets, that should remove the crackle.
A baffled echobox muffler from Flowmaster or Thrush is not going to help anything with what you have going on.
Ford Trucks for Ford Truck Enthusiasts
But really, idk how much of a difference that really makes. After I upgraded my Y pipe, and added a 4 inch exhaust to mine(no cat), I went on a trip and got a 2 mpg better than previous trips on same trip. But, didnt get that again. Than I added headers and a CAI, still didnt seem to make a difference. But it sounds alot better, and I know it breaths better. But as for seat of the pants, can't really tell the difference. as for fuel milage, my gear swap made the biggest difference. Exhaust was hardly noticeable difference overall on milage.
But yes, stock is 3 inch exhaust.
Was installed by one of the most recognized exhaust shops in Fort Lauderdale, so I felt comfortable with his opinion. Please keep in mind this was for the v10 and I'm clueless with the 5.4.
might that have been the Mad Hatter on us 441? Near st road 84/595, Or is he gone? I havent been home in a long time. That guy was the best around that I can remember in Lauderdale., But Im uncertain of his where abouts.
curios.













