4 or 5 in exhaust
Kinda out of the question, but look at MBRP's exhaust systems. Reasonably price and great fit. My friend just installed one on his truck, it took about an hour to put together and mount, and it fit perfectly. Not to metion the great sound!!! He chose 4", I think a 5" exhaust is kinda overkill unless your pushing 500+ horses...
not sure where im at in hp i would like to be in the 500S, but i wont know any time soon because i dont think there is a dyno in alaska. and shipping is really bad on stuff up here but there is a big rig shop where i can buy alll the fittings and pipe so i figured id give it a shot
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I used three 45's and one 90 the rest is straight pipe. I cut about 4" off the male end of the first 45 in front of the axle to get the height right then the rest are all just clamped together. Pipe exits right at the back corner of the bed. Use band clamps and the install could'nt be easier. If you have access to a mig welder get some 3/8 rod and just bend and weld your own hangers on the pipe. I think it cost me about $200 and about 2 hours to install.
Kinda off topic, but I have 5" on mine that I bought off of eBay for about 350...I had it on my old 12 valve and now it's on my 24 valve...if you want a 5" system just go to a diesel shop for over the road trucks...they should have everything you'd need...here's a clip of what my 24 valve sounds like...the 12 valve was ALOT louder and had more of a growl...
Click here to see Video
stock turbo? my buddy's 01 sounds just like that 
it's amazing how much different turbos effect the sound of these trucks

it's amazing how much different turbos effect the sound of these trucks
Kinda off topic, but I have 5" on mine that I bought off of eBay for about 350...I had it on my old 12 valve and now it's on my 24 valve...if you want a 5" system just go to a diesel shop for over the road trucks...they should have everything you'd need...here's a clip of what my 24 valve sounds like...the 12 valve was ALOT louder and had more of a growl...
Click here to see Video
I built my own 4" exhaust, and the parts through summit racing I beleive was about $100 for just tubing (2 4' sections), clamps, and a short radius 45* bend. The expensive part was the Aeroturbine muffler, straight through...I think it was $180. BUT the quality is remarkable, and liftime warranty...and its polished stainless, and it sounds really nice. Not too raspy like a straight 3" i had.
Oh and the 3"-4" reducer, which I had to cut the 3" side down a bit to keep nice and close to the elbo on downpipe.
I didn't bother turning out, just did a 45* cut and left it about midway between axle and front of bed. If you don't like interior noise, turn it out, cause it kinda resonates at 2k-2.2k rpm, above that can't really hear much at all.
For hangers I had some 1/4" threaded stainless rod laying around, so I bent one end to hang from the rubber gromit things, and the other end around the pipe in a "U" shape. A peice of C-channel (3/4" i think) across the top of the U nutted down to clamp the pipe. Works like a charm, and it was easier than me burning through pipe with the stick welder (I'm gettin better though.)
Oh and the 3"-4" reducer, which I had to cut the 3" side down a bit to keep nice and close to the elbo on downpipe. I didn't bother turning out, just did a 45* cut and left it about midway between axle and front of bed. If you don't like interior noise, turn it out, cause it kinda resonates at 2k-2.2k rpm, above that can't really hear much at all.
For hangers I had some 1/4" threaded stainless rod laying around, so I bent one end to hang from the rubber gromit things, and the other end around the pipe in a "U" shape. A peice of C-channel (3/4" i think) across the top of the U nutted down to clamp the pipe. Works like a charm, and it was easier than me burning through pipe with the stick welder (I'm gettin better though.)
yep, stock turbo...but the silencer ring is MIA and the lid for my AFE intake also got left off...I don't like that much whistle, but i'm starting to...the old 12 valve really growled with that exhaust...
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