hey everyone, i was thinking after i do my lift next weekend me and my bud want to re do my exhaust system. starting with replacing the manifolds with headers and going all the way out the rear end. i was wondering what your guys' opinions on what headers i should get are? I was thinking Summit Racing, Gibson, or JBA headers. they would be shorty because they dont make long tubes for the super duty 5.4, at least i couldnt find any. also for what mufflers to get, i want some mufflers that will make my truck sound nice and deep without making it too quiet. and lastly, what diamater tubing? i was thinking 3in. thanks!! 2004 f250 5.4 2v

 

You want to do 3".

I have a a Cherry Bomb Vortex center in/offset out muffler. I really like it. Not even noticeable in the cab, but sounds good outside.



I plan on going with JBA headers. I think JBA or Gibson will work fine. Sometimes you can find them cheaper on Ebay.

The headers are not the big boost though, you want the SPD y-pipe for maximum gain.

Here is my exhaust install. Headers and y-pipe are still on the to do list.
https://www.ford-trucks.com/forums/1...l#post15608102

 

If you really want to try something, get a shop to do true duals with dual high flow cats and an H-pipe afterwards. There were good reviews on it with the 3V 5.4L.

https://www.ford-trucks.com/forums/1...w-exhaust.html

 

I would do something similar to what wizkid referenced. I fabricate custom exhaust for several different applications and if it were me with the 5.4, I would stick to 2 1/2" pipe all the way out to the tips of your choice. Make sure to incorporate an H pipe. It will balance out the cyl. banks and provide low end torque. The 5.4 being naturally aspirated would benefit more from the exhaust velocity of a 2 1/2" pipe . I wouldn't go larger than that, IMHO, either way it sounds like the the guy in the attached link was very happy with his exhaust, hope you see the same results.

 

The 3" single exhaust is what it had from the factory which is why I did a 3" new muffler. I definitely agree with the 2 1/2" on a true dual setup.

 

Yes, single all the way out, I would bump to 3", agree. I did a single into dual for my buddy's 12 Eco Boost. Fabed-up a 3" front pipe, to replace the factory 3" to 2 1/2" reducing pipe. The 3" front pipe goes into a dual chamber muffler with 2 1/2" tail pipes, side exit similar to stock with 18" SS tips. His wife says it is too loud, so that system will go on Craigs list and I am bending up an identical system with a 3" resonator and a turbo muffler.

 

Is that supposed to be a video? if so its not working for me. and yeah i know it wont give me great gains, mostly doing the headers because my manifolds are rusted to pieces and also for sound. and im from what im hearing 2.5 in with true duals all the way out is the best way to go. and good thing is i dont need a shop to weld the h pipe for me, when one of your best buds knows how to weld professionally

 

i hope to see the same results too, and sounds like you know your stuff. i think ill go with 2.5 in exhaust.

 

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Try this: http://vid286.photobucket.com/albums...psqndiurkc.mp4

 

I would probably go with something like this for the catalytic converters.

MagnaFlow Universal Spun Catalytic Converters 53956 - Free Shipping on Orders Over $99 at Summit Racing

And don't forget to check if your truck is equipped with EGR. The headers you buy depend on that. My 2002 does not have EGR.

 

I have been accused of alot of things, but never of knowing what I am talking about. J K.
The converter wizkid recommended are nice and the price is reasonable with the free shipping Summit offers. Just keep in mind if you do dual converters you will have to weld in O2 bungs up and down stream of each for a total of 4, OR see if the same style of converter is available with the bungs already welded in. Will be a bit more, but save time and cost in the long run.
If you have a local shop bend up a system for you request 14 gauge aluminized cold rolled steel or 16 ga. stainless if you have deep pockets. Most shops use light gauge hot rolled because it is easier to bend and work with, also cheaper. You can tell lighter ga. pipes if the bends have "wrinkles" in the inside diameter. The shop or manufacture uses" wrinkle dies" so the thinner wall pipe doesnt kink on the inner radius of the bend.
Keep us posted on your progress

 

That's some good advice right there.

One nice thing about 99-04 is they only have 2 sensors before the catalytic converter.... one in each leg of the y-pipe.



If you get cats with the bungs already on them, you'll need plugs for the rear. And you'll also need O2 sensor extension harnesses. If you just have them install the bungs in the new down pipes, no extension cable should be needed.

This is a nice write up if you haven't seen it yet.
2004 F250 Broken Exhuast Manifold Stud

 

If you're going full custom and you can get away with it I'd just do away with the cats myself.

 

That's what my plans are as it is I live in north Idaho I mean people roll coal on to cops cars on the highway and they don't care