Best sounding muffler?

FashTaco · Nov 8, 2020

Check out Carven - they’d get my money if I were to do it again.

Torspd · Nov 12, 2020

Probably one of the best sounding V6's I have ever heard.

rj_taco said: ↑

Just wanted to share my exhaust build in its own thread vs posting updates on the Ov TT thread.

Reason why I decided to do this was to get rid of the stock exhaust in preparation for the twin turbo kit (PowerMax, full fuel upgrades) to improve flow and sound and learn something new. In my opinion the stock exhaust has several limitations, from inadequate pipe IDs and bends, to unequal y pipe lengths (for sound).

I decided on a dual 2-1/2” exhaust after reading and watching videos on different V6 twin turbo setups. The original plan was a divorced system, but settled on a X pipe design to incorporate a cutout. In the end my goal was to have a flow through system that was quiet when needed, no drone, no rasp, no pops/bangs and made to last.

Parts (all 304 SS):

2 bolt flange: Amazon, 2.5” Stainless Bros 603-06320-0000
Gasket: Amazon, HYCC 2-Bolt 2.5''
Exhaust pipe: Amazon, Squirrelly 2.5" universal kit 16 ga - SPP FABKIT-5
Resonator: Amazon,Vibrant Ultra Quiet - 1141
Muffler: Amazon, Borla ProXS - 400286
Cutout: Amazon, Keenso 3” vacuum activated, normally closed - Keensogbwoqer15z-02
O2 bung: eBay, fab-pro notched
V-bands: eBay, Yonaka YMVBFC25
Over axle mandrel bend: eBay, PLM U L J (didn’t use most of it, would not do this again).
2.5 to 3” transition: eBay, fab-pros
3” pipe for cutout turndown: eBay, khaos-Motorsports 90 short
Exhaust tips: eBay, catinbow 2.5” to 3” double walk angled (cut off)
Hangers: eBay, Yonaka 1/2”x9.5”

Welder and parts: Amico TIG-225 that I modded for pre/post flow control, variable pulse, tack mode and foot pedal. CK worldwide 17 torch, Furick FUPA #12, .045/1/16” 308L filler, 3/32 blue electrode.

Weld settings: 100% back purged @ 5-10 cfh, torch mostly at 20-25 cfh. Pipe to pipe with bad fit up, 55 amps (w/foot pedal) .045 filler. Pipe to pipe with good fit, 1.5 pps, 25% peak, 55 amp peak, 10% background amps, autogenous (no filler). Flanges were done mostly with the same pulse settings @ higher amperages with 1/16 filler.

Band saw: Amazon, 4”x6” WEN 3970 T w/ starrett blade

I had no previous experience doing this, just watched videos (kudos to Jody, weldingtipsandtricks YouTube channel) and learned as I went. I took time to practice and hoped for the best both in fabbing and what it would sound like.

A few pictures, feel free to ask any questions. I will do my best to answer.

Started with X pipe, from 2 U-bends cut at 30% ID and 45 degrees:

Then added a 90 using pie cuts (9+9 degree, short radius).

Fabbed left and right sides, which replaced the secondary cats with vibrant resonators. Left side is a 55 degree offset of center, right side is 45 degrees.

Added v band flanges to X pipe and welded it up:

3” cutout parts (pie cuts 9+9 degree):

All fitted and checked for clearance:

Welded O2 bungs and finished welding both sides:

Placed the Borla muffler as high as I could:

Added hangers (stock locations):

On to the most challenging piece! Took 41 pie cuts and lots of time. I wanted to be able to fit a 33” spare (move bracket) and allow full droop (RXT + ext. length FOX 2.5), I still want to fab a turn down that can be swapped when needed. I’m changing the hangers to BAMF as well.

Onto the exit, I wanted the tips to be as high as possible for looks with enough clearance. I had to move the hanger further up as well.

Here is the sound clip of a warm start, revs to 4-6k. Ov 2.0 tune. No other mods, stock air box. Overall I’m very pleased with the tone and volume, no rasp what so ever, no drone and quiet when needed. My calibrated butt dyno (not) tells me there is a perfomance improvement. The truck feels more lively on low RPM for sure, more noticeable up top, which is surprising given the pipe diameter.

https://vimeo.com/459999807

I still need to hook up the cutout, which will give the tone a bit more of an attitude. The truck is back in the basement for other mods prior to the twin turbo install, which hopefully will happen by mid October. I’m expecting the exhaust tone to change a bit with TT’s (catted down pipes) and be a bit quieter because of the turbos. I’ll update as the install moves along.
Click to expand...

93yotasr5 · Nov 13, 2020

I like my JBA cat-back system. It’s a little louder then the TRD. But for $150 it was hard to pass up.

my first choice would be TRD cat-back though.

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Best sounding muffler?

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Best sounding muffler?

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FashTaco Jungle Asian

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Torspd Tor-nication

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