I thought the Pypes system I started with was well worth the money. I built my own mufflers and cut the tail pipes to dump behind the rear wheels. Otherwise, it's as they intended. I'm still on leaf springs in the rear though I'm quite low. Plenty of clearance everywhere around the axle for me.
For sound, I prefer Magnaflows. They'll get loud when you put your foot into it. Otherwise, it's a smooth, clean sound to me. The longer the muffler, the quieter. I built mufflers similar to Magnaflow's design. I only had room for 3" think mufflers and they don't make them that thin.
I can't help with header brands. My suggestion is 1-7/8" diameter primaries. I wouldn't go full 3" on the exhaust pipe. Maybe start with 3" and neck down to 2.5" before the x. Or, go with 2.75 the whole way if you're building from scratch. I'd be afraid 3" will rob too much low and mid range torque to give you higher peak power. That's not worth it in my opinion. Not to mention how much louder 3".
Car's coming along well. Thanks for keeping us updated.
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Trey
Current ride: 2001 BMW 540iT soon to be manual swapped.
Former rides: 1979 Trans Am WS6: LT1/T56, Kore 3 C5/6 brakes, BMW 18in rims
00 BMW 540i/6: Suspension, wheels, and ACS bits.
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