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I would go with the Thorleys. They fit great, have all the necessary emissions hook-ups, don't leak, and have a good warranty.
I have a set of tri-y's on my '87 and I'm glad I spent the extra money. Plus I like the fact that both headers exit on the passenger side. It's a lot easier to run exhaust on a 4x4 that way.
I've had good luck with the Heddmans. Of course I live in dry Arizona so snow/salt isn't an issue. They won't last forever but you're not paying a ton for them either. The coated ones may be a good mid-line choice. I'd go with 2 1/2" tubing and the fewer the bends the better. I used prebent pieces from J.C. Whitney to make my exhaust on my 73 F350 w/460. The pieces are mandrel bent so the diameter stays 2 1/2 all the way through the bend.
I installed Banks Power-pack about two years ago. Expensive, but a great product. Stainless steel, 5/8" flange, milled flat after welding. Good instructions, good fit. I purchased the complete kit, but it's possible to purchase the headers only.
Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath
Slideshow: Called the Fortress, the 850-horsepower pickup combines Raptor underpinnings with military-inspired features, survival equipment, and a starting price of $285,000.