I just inherited an '05 250 from my dad, and at one point the cat got clogged so he had it taken out with the muffler so its just a straight delete. It sounds okay at idle but around 1950 rpm and above its raspy and nasty. I would like to keep 60-80% of the volume but even out the tone. Assume I live somewhere where there is no dbA limit and cats are not required. What are my low cost options? How much cutting and fabricating will be needed??

Thanks

 

honestly id buy a quality glass pack type muffler from Borla, Magnaflow or Cherry Bomb. They offer different length's so a longer one will be a little mellower and a shorter muffler more louder and raspy. I had a 18" long Magnaflow on my 2004 F350 with 5.4 in my sig with no cat and man that was the meanist best sounding 5.4 ive ever heard! I removed it because towing my 20ft CC to Lake George two years ago drove me nuts with that loud dual pipes towing all that weight.

 

- http://www.borla.com/products/specialty.html
- http://www.borla.com/products/xr1.html
- MagnaFlow Exhaust Products - For Trucks, Suv's, American Muscle, Diesel, & Sport Compact Vehicles

 

Do you know if the stock pipe is 2 1/2"?

 

I have a pair of dynomax super flow mufflers on my truck. Good sound, no drone, and not very loud either.

I believe you'll need a 3" in/out muffler. Make sure to get the larger model they make. I had the short one on my truck and it was too loud (with cats).

 

stock is 3"

 

This right here inexpensive. Look to a muffler that is stainless steel too.