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Too bad you weren't closer, you could have my old one! :D

What are your plans for the car? How much money you want to spend?

With the 3.8, you'll never get that V8 sound so keep it toned down. I went with a Magnaflow DI/DO resonator and the mandrel bent pipes with Dynomax Super Turbo mufflers.

Joe
 

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I'm not sure if you are committed to replacing your cats but with the age of our cars, the cats are a good thing to consider replacing when you upgrade your exhaust. What works for you may be determined by the amount of emissions inspections you have to go through.
I went bigger than needed for my 5.0 (2-1/2" true dual mandrel bent with a large intake upgrade also) but you might do fine with new cats/high flow cats and standard pipes. I first tried true dual with no cats and the xpipe but it was too loud for daily driving even if it was free flowing. A second try with high flow cats and the Magnaflow dual in/dual out resonator quieted things down.

I bet you'd do well with a bigger than stock cat back system and new cats all around. The third cat being eliminated or replaced with a Magnaflow resonator. Probably be louder but more free flowing. Cheapest will be single exhaust after the third cat to save a muffler and some labor.
 

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Discussion Starter #4
Cats were replaced 3-4 years ago. Want it quiet, dear ol dad told me you can get away with anything if you do it quietly! ;). Duel outlets would look good. Going to keep the car because I like it and it only has 85k on it.
 

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If your goal is dual outlets and keeping it quiet, I would say look for a stock SC system, and possibly delete the resonator behind the 3rd cat, as that is the most restrictive part of that exhaust system. Other than that, the 3.8NA isn't going to make enough power to need anything larger, the stock mufflers are great at keeping down the drone inherent in a V6, and the stock systems generally last much longer than the aftermarket ones since they are made of a low-grade stainless steel, which is much more durable than the aluminized steel that cheaper aftermarket setups use.
 

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Discussion Starter #6
If your goal is dual outlets and keeping it quiet, I would say look for a stock SC system, and possibly delete the resonator behind the 3rd cat, as that is the most restrictive part of that exhaust system. Other than that, the 3.8NA isn't going to make enough power to need anything larger, the stock mufflers are great at keeping down the drone inherent in a V6, and the stock systems generally last much longer than the aftermarket ones since they are made of a low-grade stainless steel, which is much more durable than the aluminized steel that cheaper aftermarket setups use.
That sounds like a good plan. Will see what I can find. Do I have to go to Ford for the stock system or will walker or NAPA or someone carry it in stainless.
 

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I meant get a used system off an SC, as it will probably still be in good shape.
 

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Related to Madmikey's comments would a rear half from a V8 model fit? I saved the front half of my stock exhaust but not the rear. It was pretty easy to remove and if only a little custom work is needed to remove the resonator and attach the old setup it would be pretty easy and cheap. I'm sure you can find some factory stainless exhaust setups in yards somewhere. My factory mufflers kept my .302 pretty quiet.
 

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I believe the back half will bolt right up, but I'm not 100% sure, but worst case it wouldn't be too hard for any exhaust shop to weld something up to mate them together.
 

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I found a complete, one piece OEM exhaust from a 95 Thunderbird at the yard and it fit with no issues, I just used a reducer to get the larger 4.6l exhaust to fit my 3.8l exhaust size. All of the mounts exist already on the 3.8l to mount the 4.6l exhaust to the car. Make sure to bring home the rubber mounts from the yard to use on the drivers side muffler.

I did this back on 2010 and the exhaust and mufflers are still working great.
 

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Sounds like a good way to go, but with emissions laws, a lot of state's junkyards are required to remove the exhausts from all cars, at least the catalyst section.

Al
 

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Sounds like a good way to go, but with emissions laws, a lot of state's junkyards are required to remove the exhausts from all cars, at least the catalyst section.

Al
You are correct. And this was from the CAT back, so it would not apply.

Though, as i recall, this junk yard did not remove the cats, but I do believe there are customers that do remove the cats for the money.

Not sure if I really ever noticed.
 

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Sounds like a good way to go, but with emissions laws, a lot of state's junkyards are required to remove the exhausts from all cars, at least the catalyst section.

Al
Here in California, they remove the catalytic converter(s) from a vehicle. The rest of the exhaust system remains in place.
 

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Discussion Starter #15
Thanks for all the help. May have a line on a sc being parted out. If I eliminate the resonator will I gain a drone with duels? Two mufflers should be better than one?
 

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Thanks for all the help. May have a line on a sc being parted out. If I eliminate the resonator will I gain a drone with duels? Two mufflers should be better than one?
Research and experience have taught me, drone is caused by reflective style mufflers, i.e., Flowmaster 40. Mine are coming off asap, to be replaced by Magnaflow performance style. Had I been aware of what to expect, I would never have installed the Flowmasters.
 
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