02 SXT and LTH considerations

[Aikidoka]

I've been doing a bit of research on things I can do with my 02 SXT. It is at 133K and I've only really done the NGKs, Redline MTL, and booger bushings. Most of that was recent. For the exhaust I am looking at doing an OBX long tube header and a Magnaflow spun 2.5" cat. From what I've read this will bolt up to the head and leave me with a 2.5" out after the cat. Now for the muffler I have looked at possibly Vibrant or Thermal. What I read on both is that they are 2.25". Most people write that 2.25" is fine for the 2.0L but that 2.5" is not overkill, assuming that there isn't a lot of motor work. Going down to 2.25" seems like it should not be an issue in my case. Is there any point to trying to keep 2.5" all they way to the muffler? Overall I will probably do the UDP and try to at least track down a magnum intake.

Also, I have seen some pics of bumpers with cutouts to run single tips on each side. Another option is dual tips on one side. It seems either will require these cut outs as the SXT has a turn down. What would be a good tool to do a rough cut and what would be the best way to smooth it out?

[occasional demons]

As for the exhaust, you could reduce it before the "S" bend after the mid pipe. The gases will be a little cooler by then, and it will help keep the velocity up. A stock SRT exhaust is necked to 2.00" so 2.25" back there should be fine. You aren't going to be making over 200 hp, so it shouldn't be an issue.