Finally!  I started the plans for my custom exhaust in September 2004.  I purchased the Aeroturbine 3030 muffler on ebay in September, received my first donated stock system in October, my second victim stock exhaust in January 2005.  On May 1, 2005, I finally managed to get together with my friend Andy for him to help me with fabrication and welding.  The first night we managed to complete the modifications to the Y pipe.  Our second effort on May 15, 2005, we completed the full system.  One of the goals we had was to make our changes so that the new system maintained the stock mounting locations and flanges so that if necessary for any reason, my stock system (currently hanging on the wall in my garage) can be bolted back in place with just a few minutes of effort.  The other goal of course was to increase performance and tone.

Click here for some day after pics and one more sound clip...

Stock Y pipe where we first started cutting out the restriction
Restriction removed to open the inside of the Y for full flow
The Y must be realigned for the center in/out muffler, so we made the adjustment where we opened the Y
My first ever welding experience!  I welded the seam closest to the torch.  You can't tell in this pic, but the torch is pointing to a mountain that I built while trying to learn how to fill a 3/16" hole.
My good friend Andy.  Without Andy, I would not have been able to do this.  He welded most of the system and provide the fabrication experience.  He even had the patience to teach me how to weld.
Top side of the new Y

Bottom side of the new Y 

For the "new" tailpipe, we started by welding 2 stock tailpipes in parallel
Stock outlet elbows were cut out of the stock mufflers to make our new dual outlet
This video is the stock exhaust with no modifications

Good bye stock sound!
After unbolting the stock exhaust, this clip is how sweet is sounded with only cats & resonators

Action shot!  Does he remember what he learned 2 weeks ago?
I know Andy remembers!
AT3030 welded to new dual outlet and dual tailpipes
Throwing fire!
Surprise!
What's he doing under there?
Uh oh...  He isn't really going to...
He is, he is!  He's welding under my truck!  Thankfully the gas tank is on the other side!
Welding light @ night!
Stock vs Custom
Doesn't the new muffler and dual outlet just look so much better than the stocker?
Not much visual change here, but the flow is far different!
We installed the custom Y, AT3030 muffler and custom dual port outlet (no tailpipes)

Complete custom system installed.  The finished product!

In-cab drone on the freeway (60 - 80 MPH)