I have a 2005 F150 ext. cab STX 4.6L. I have been through a lot with my exhaust. First I had a piece of crap truck shop mess up the entire exhaust then charge me $300 for it. I wanted rear dual side exit. They gave me rear dual side exit/ rear exit.... it came out at the corners of the bumper. Basically looked like crap. When I took a look under at the job they did, they blew holes through the DOUBLE WALLED PIPE!!! they said they welded it all up really nice??? It looks like they had a 3 year old weld it. So I took my angle Grinder and cut it off and made it just dual rear exit. I thought it looked awsome, until I walked to the side of my truck (where you can see the aluminum pipe connected to the polished tip) I thought it looked cheap and tacky. And it will look worse when I get my lift put on. Now I am planning to rip out the whole exhaust, nearly $400 down the drain. I want to get new stainless steel headers, and run a full stainless steel exhaust into my Super 40 (which I already have) out the side before the rear tire. Like on the Lightning. I will have a different body shop weld it all up really nice (like a roll of quarters), then I will grind down the welds and polish all of it so it looks BEAUTIFULL. Now if u have read this far, my questions are... 1.has anyone been through this, 2. has anyone ran full stainless headers to a muffler and out before the rear wheel, 3. what kind of headers should I get (price is not an issue, I want quality). I really appreciate any of your comments, and im not in a hurry I have to pay for my new Harley Grille first.

 

i havent done any of the things you are going to do, but it sounds like a really cool idea. i would think that most big-name header companies would be a good place to look first. installing the headers will be a BITCH, but it will be worth it. i also think that a fat oval exaust tip would look cool. good luck.

 

i have a 4.6 too and i have come up against the same problems you are having. dynamaxx prolly makes the best longtube headers for an f-150, but they are for a 5.4. the starter has to be clearanced and the egr tube has to be altered. i was opting for an xpipe (i wouldnt be trying to pass emissions so cats wouldnt be a factor) after the collectors. make sure you have a good tuner/programmer to clear your codes if youre doing this (troyerperformance.com will pricematch any legit programmer/tuner, and the xcal2 is a sweet deal...). ill research the response to my question like yours and post the link...

 

here ya go...hope this helps:

https://www.f150online.com/forums/sh...d.php?t=273748