Hey guys, I installed an exhaust on my 4.8l rcsb for less than $250! I was looking into the Magnaflow system that dumps before the axle, but was concerned that the muffler that they use would be too loud since my cats are empty .
So, I purchased a magnaflow 12641 muffler, which is a 30", 6" round muffler with 3" in and out. I then purchased a 5 ft section of 14ga 409 stainless pipe from ebay as well as a 30* bend section of 16ga 409 stainless with 3 -3" band clamps.
The 14ga stainless pipe is REALLY thick, and I'm pretty sure it will outlast the rest of the truck. I cut this piece down to 27".
I then cut out the two bolt ball flange connector about 1" back on the y-pipe, since it tapered down to a 2.75", butted the 27" pipe against it, added a band clamp. the magnaflow muffler then slipped over the 3" pipe and I clamped it together. The band clamp lined up with the hanger, so I used a piece of 3/8" rod bent it to slip into the hanger. I used the last band clamp for the 30* bend and it lined up to the second hanger, so I used the threaded rod with washers and nuts bent to fit in that. Anyway, check it out! The 30" muffler sounds great, a little loud without cats, but it's not too bad.

 

Nice. I need to do something with mine. Mine dumps before the bed after the y-pipe and a tiny Magnaflow bullet. It's too dang loud. When I did this exhaust I was driving 15 minutes per day or less. Now I'm driving 30 minutes each way to and from work and it's killing me.

 

This 30" monster seems to do pretty good, even without cats. It's a bit louder than the stock muffler, but not so loud that it's annoying.

 

Id weld those connections before those band clamps wear out.

Looks good

 

I've had pretty good luck with the band clamps. I had the same muffler on my GTI, and it worked well for over two years. Knowing me, I'll probably switch it up in a few months anyway, and do a v-band connection and weld the rest.

 

Mine is as cheap as it gets. Cats replaced with 3" straight pipes($10 for pipe, a few hours of time if you weld), "catback" section is a flowmaster welded to the flange and a bent pice of 3" coming out before the tire. Less than $70 including the ancient 40 series. Fubar but it sounds decent.

 

mine was cheaper got a muffler for$4 at summit with gift card and muffler shop threw together old exhaust and a 3inch turndown for $19 at jegs.