Got a 460 in my 350 4x4 with long tube over the frame headers. Those dump into maybe 2 1/2" pipe into some flowmaster looking knockoffs and exit before the rear tires. It sounds good but wanting a deeper sound. Thinking of going to 3" piping out of the collectors into a good deep aggressive sounding muffler and would love to have it exit out the rear but don't know where to cross over the frame without it looking to hoaky. If not, before the rear tires how it currently is wont hurt my feelings. Any advice on what muffler sounds deep and aggressive and also how to route the pipes to the rear? Ive looked on you tube on sound but haven't really found anything

 

I had good luck with a 3" mandrel bent kit that I worked up with a set of flowmaster mufflers. It's borderline too loud but for my truck it's perfect. The packaging on my truck is different from yours, mine is lowered with a narrowed rear end but it would be similar challenges to snake around a transfer case. Something else I've put into a couple of my exhaust systems is v band clamps; I've had really good luck with them and it makes pulling the exhaust out in sections really easy to do work on the truck. I also went to the junkyard and spent some time with a cordless sawzall cutting out some oem hangars and the rubber parts, they are really nice heavy pieces.

 

Try and put a x or h pipe in it.

 

Several years ago I took the cat and exhaust off a 1990 F250 and welded in a muffler off a 1997 Powerstroke. Since the stock exhaust was 2 1/2", I used the bolt up flange, made a custom adapter, and then welded up the Powerstroke exhaust. I can tell you that was one of the deepest sounding exhausts I ever heard. Little to no backpressure(you do need some but diesel systems are probably the free-est flowing). It gained immense power, almost 4-5 mpg on the highway at 70( first trip I got 17 mpg). It would echo off canyon walls, etc if you took your foot out of it. 😛. If I had a 460 again, I'd find someone taking off their stock Powerstroke exhaust... Pretty much junk to them, offer them $100...put a wanted ad on Craigslist, etc to locate one. Nobody else will have a truck that sounds like it.

 

Actually went out and measured and the tail pipes are 2 1/4".. So going to a 3" would make a big difference I think. I thought about getting a couple straights and some 45 deg bend pipes and making my own. I've been needing to learn how to weld anyways

 

Get the best welder you can afford... if ya get a lil one, over time you will want a bigger one. I started with a Miller 140 and now also have a Miller 211.. it's kinda nice not having to switch wire spools from body work using .024 wire to .030 wire for frame work.

And once you start welding, you ll never look at metal the same way again.

On your tube sizing, 2.5 inch duals is all that's really needed given the typical RPM and HP numbers. Alternatively, 2.5 inch duals into a 3-inch single outlet muffler is acceptable. Your call whether the marginal increase in cost, which is significant, for a dual 3-inch system is worth it... just know it is technically an overkill.