Hokay so, I have an 1996 F150 5.0L 302. It is completely stock as of now, I have decided that I am going to (over time) build it up. I am going to start with the exhaust. I have my eyes set on full length headers that will fit no problem there, I was hoping to find out weather the stock pipe will marry up to the new headers, and if it will cause any issues with back pressure.

Does anyone know what I could/should do?

 

No it wont. Shorty headers bolt up though.

Which ever you choose, dont buy a cheap brand.

 

cut it off right past the EGR pick up haha, best sound ever, it will sound like poo the first few times you drive but will break in and sound sopooooo nice, i did it on my 4.9L bet it would sound even better on the 5.0!

 

Full length headers will require custom x h or y pipes. Shorties will fit stock. Like the others said get good quality. You will be glad you did when you install them. Cheap headers have sealing problems and are hard to install. Make sure you have a place for your o2 sensor and egr or performance will suffer and the cel will come on. I recommend keeping the cats in place or if you prefer stepping up to high flow if they are legal in your area. Removing cats and the air pump gains no real performance as long as they are working properly, and on a 96 you will get a cel or you need to defeat the cat sensor. Also keep in mind it is illegal to defeat any smog devise any where in the US and new laws are always being made. That's all my preaching about that. Cutting the tail pipe before the axle is one of the best modifications for performance and sound. Not to mention you drop 10 pounds of dead weight. Mufflers are personal taste. Turbo or chambered mufflers are the best for performance. Glass packs ( cherrybomb ) are almost as good if you prefer that sound. Pipes should be about 2- 2 1/2" for dual or up to 3" for single. Much bigger and you loose velocity and reduce scavenging.

 

Geez that's a ton of help! Thanks I am almost thinking if I go with shorties It will be way easier and I don't have to do any more modifications. Maybe down the road I'll go with the full length headers!

 

Full length are said to provide better low end torque. Most dyno numbers I've seen however are close enough that I don't think you would notice a difference on a street engine. The difference between stock iron and steel tubes is pretty good though. There are also complete kits from summit racing, LMC truck, national parts depot and similar places

 

So the next question is Ive been looking into mufflers now i have had the Flowmaster super 40 on a past vehicle and it sounded pretty good, but I was wondering if there is anything out there that gives a lower resonance at idle and of course a louder tone at higher rpm, but still keeping that throaty sound without that higher snap of lets say a glasspack.

 

Your best bet will probably be to look around on YouTube and see what sounds good. Don't forget though its the whole system that effects the sound. Even the intake. An open element intake will give a more throaty sound.

 

i know i already threw this out there, but the cutting it off delivers great low tones at lower rpms and just screams a the higher end