OK - So I'm back at this. The driver side works fine without mods other than cutting off the welded rear flange. The passenger side needed some mods. I cut and taped it up to mock it up.
I think this will work if I get it welded up. What do ya'll think?
Now the Explorer 5.0 had a "rear" double cat with no rearward O2 sensors so I think this was just to further polish the exhaust fumes. Should I add these anyway? I don't think that rear cats did anything with the 5.0L PCM. I plan to put some heat shielding around the front cats to protect the tranny and frame. I'll cut off the welded flange end of the drivers side and tie these 2 cat outputs which are 2.25" OD into a 2-into-1 muffler and extend a 2.5" OD to a resonator or maybe not do the resonator and go straight to the tail pipe. If the cut on the welded flange is too close to the existing O2 bung, I'll use one of these clamp style O2 sensor adapters.
Instead of a 2-into-1 muffler, maybe I use a Y-pipe instead and use a 1 to 1 muffler? I'm looking for a quiet exhaust system. Thoughts are much appreciated. It won't be easy just to take this down to the muffler shop and have them fab something up.
