I finally pieced together a few clips and pictures of the truck. Stats are at the beginning of the video, but I'll list them here as well.
2005 Ford F150 SuperCrew FTX
F150Online.com Exhaust Thread
More Info about the truck and Roush SuperCharger & CAI:
The main reason why I was able to build out this system, and do the other upgrades to my Ford F-150 is due to my business. You can learn more about it by clicking the link below.
Looking for something else in life? -
It's important to remember when building a custom exhaust that you need to take a look at your vehicle over all and determine what you need and how you want it to look. Size and type of your engine will make a difference on the size of exhaust pipe that you need. The bigger the engine the larger diameter pipe you can use. Or if you have a smaller engine, but you are using a SuperCharger or TurboCharger then you can get away with using a larger diameter since you are forcing more air through the system.
You also need to determine if you want to do a True Dual exhaust (two separate pipes coming from the headers all the way out to exit) or go with a SIDO (Single In, Dual Out) setup which is the two pipes come from the engine headers into a Y pipe then into a single tube into a Muffler that then recreates the two exits. The third option would be to use a SISO (Single In, Single Out) setup which is the same as SIDO besides when it goes through the muffler it stays as a single tube. this is pretty standard on most new vehicles.
As far as Performance:
1 - True Duals
2 - SIDO
3 - SISO
You have a couple choices when you determine you want to do a True Dual setup. You will need to determine if you want an X pipe or H Pipe for a crossover. You definitely want to choose one of these setups over going straight from the headers to the exhaust. The two styles allow the exhaust to share the grunt of the work to move the air through the system. Since one side always has to work hard to push the exhaust further. The H-Pipe is generally cheaper and less effective than the X-Pipe. The X pipe generally sounds smoother and adds a bit more performance.
As you can see from the top of this, I choose to go with an X Pipe with my F150 True Dual Exhaust setup since it is often called the pinnacle setup.
After you have determined what style to use and crossover you will then need to determine how you want your exhaust tubing be made. The two main choices of types are stainless steel and aluminized steel. Aluminized is the old school way. Stainless (304 over 409) is the best. You then need to decide how you want your tubes bent. You can get Mandrel Bend or Crushed Bent. Crushed is where they just take the pipe and bend a corner in it, leaving the corners/bends crushed in (restricting airflow). Mandrel bends leave the bend almost 100% unrestricted allowing the most air flow. It is also the more expensive option.
Next you will need to determine which type of muffler to get. Baffled, Chambered, or Flow-Through (Straight-Through). Each will have their own sound and performance.
Best Performing: Flow-Through (Straight-Through)
With the baffled, you will lose a lot of sound and performance due to the baffling inside the muffler. Chambered are similar to Baffled, except a slightly better performance and sound. Flow Through is the cream of the crop when it comes to performance due to less restrictions.
Next you would need to determine which Catalytic Converters or Cats you want to go with. How many does your system currently have. Some Ford F-150's and other models came with 4, but my 2005 F150 only had 2. Catalytic converters are used to help clean the exhaust as it passes through by heating up and reducing the amount of harmful gasses. You can choose to stick with OEM Cats, High Flow Cats, or No Cats.
Best Performing: High Flow Converters
Using none could cause issues with your vehicle or even get you a ticket in some states. OEM is restricting on the system but does help eliminate the most harmful gases and is required in some states like CA. High Flow Catalytic Converters are by far the best for a high performance system. They increase sound quality, volume, and overall aggressiveness of an exhaust.
Lastly, you will need to determine how you want the exhaust to exit from the vehicle. On my Ford F-150 I chose to angle it to the corners and slightly down towards the ground. This has become a popular style vs doing it straight out the back. It really makes the true dual exhaust sound good going through tunnels and overpasses.